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WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California 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 owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence 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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2006 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. 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.
2007 RANGER 4X4 500 EFI Owner’s Manual
P/N 9920635
2
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TABLE OF CONTENTS
Vehicle Identification Numbers. . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 100
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 116
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3
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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. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Key
Number
####
VIN
Engine Serial Number
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number ____________________________________________________________
4
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions of the decals on the vehicle carefully. If
any of the decals depicted in this manual differ from the decals on your
vehicle, always read and follow the instructions of the decals on the
vehicle.
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.
Container/Passenger/Tire Pressure Warning
WARNING
Remove flammable material
containers from box before filling.
+
• Passengers can be thrown off. This
can cause serious injury or death.
• Never carry passengers in cargo
box.
Maximum 2X4 Box Load 850 lbs.
Maximum 4X4 Box Load 1000 lbs.
Maximum 6X6 Box Load 1200 lbs.
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI):
RANGER - 2X4 and 4X4 FRONT 10 REAR 10
RANGER - 6X6 FRONT 10 CENTER 10 REAR 10
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO:
RANGER 2X4 and 4X4 is 2750 LBS. RANGER 6X6 is 2900 LBS.
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information.
5
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SAFETY
Safety Decals and Locations
Cab Frame/Seat Belt
Warning
Clutch Cover
Warning
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• 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.
Cab Frame/Seat Belt Warning
WARNING
• VEHICLE ROLLOVER could cause severe injury or death. This cab frame is
not designed or intended to provide rollover protection.
• ALWAYS WEAR YOUR SEAT BELT for maximum protection.
6
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SAFETY
Safety Decals and Locations
Shift Caution
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle.
Discretionary Warning
WARNING
Shift
Caution
Improper vehicle use can result in
SEVERE INJURY or DEATH.
NEVER:
• Operate on public roads. A collision
can occur with a another vehicle.
• Carry more than two passengers, or
passengers under age five.
• Use ALCOHOL or DRUGS before or
while operating this vehicle.
• Operate at speeds too fast for your
skills or the conditions.
Discretionary
Warning
• Operate this vehicle on HILLS
steeper than 15 degrees
15°.
To prevent flipover on hilly terrain,
use throttle and brakes gradually.
ALWAYS:
• Avoid paved surfaces which may adversely affect handling and control.
• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and
rough terrain and in turns.
• 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.
7
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SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as motorcycles and cars.
A collision or rollover can occur quickly, even during routine maneuvers like
turning, or driving on hills or over obstacles, if you fail to take proper
precautions.
Read and understand your owner's manual and all warnings before operating
the vehicle.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may ride
as a passenger in this vehicle.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
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 vehi-
cle are thoroughly inspected at specific intervals.
8
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols 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 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
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.
9
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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.
• Read this manual and all labels carefully. Follow the operating
procedures described.
• Never allow anyone without a valid driver's license to operate this
vehicle.
• 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.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Helmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
• Never consume alcohol or drugs before or while operating this
vehicle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your
experience.
• Never attempt jumps or other stunts.
• 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.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Always travel slowly and use extra caution when operating on
unfamiliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
10
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SAFETY
Operator Safety
• Always follow proper procedures for turning as described in this
manual. Practice turning at slow speeds before attempting to turn at
faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized Polaris dealer if it
has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• 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.
• Always follow the proper procedures outlined in this manual for trav-
eling 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.
• 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.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skid-
ding or sliding out of control.
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• 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.
• Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on page 5 and in the
specifications section beginning on page 100.
11
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SAFETY
Operator Safety
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and fol-
low the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
• Always keep arms and legs inside the cab frame while the vehicle is
in motion.
• Always engage the park brake before getting out of the vehicle. See
page 30.
• Always apply the brakes before releasing the park brake.
• Always turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks. Gas-
oline is extremely flammable. See page 21 for fuel safety warnings.
• Always remove the ignition key when the vehicle is not in use to pre-
vent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-
342-3764.
12
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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 vehi-
cle 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) mow-
ers, 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.
13
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards while
climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when climbing
a hill.
If you lose all forward speed:
Apply the brakes.
Engage the park brake after fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service dealer check the
complete vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.
WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle's tires are designed for off-road use only, not for use on
pavement. Paved surfaces may seriously affect handling and control of the
vehicle, and may cause the vehicle to go out of control.
Avoid operating the vehicle on pavement. If you must operate on a paved
surface, travel slowly and do not make sudden turns or stops.
14
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the
operator does not know how to operate the
vehicle properly in different situations and on
different types of terrain.
All operators must read and understand the
Owner's Manual and all warning and instruction labels before operating the
vehicle.
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, including
dirt or gravel.
In many states it's illegal to operate vehicles of this type on public streets,
roads and highways.
15
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle after consuming alcohol
or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving a RANGER requires your full attention. DO NOT drink alcohol or use
drugs or medications before or while driving. They will reduce your alertness
and slow your reaction time. In most states and provinces, it's prohibited by
law to drive while intoxicated or under the influence of drugs.
WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and operating
conditions, and your experience.
16
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator fall through
the ice.
HOW TO AVOID THE HAZARD
Never operate the RANGER on a frozen body of water.
17
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your RANGER before each use to make sure it's in safe
operating condition.
Always follow the inspection and maintenance procedures and schedules
described in the Owner's Manual.
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
You may come upon hidden rocks, bumps, or holes suddenly, without
enough time to react.
18
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver's license should operate a Polaris RANGER.
Even though a child may be within the age group for which some vehicles are
recommended, he or she may not have the skills, abilities, or judgment
needed to operate the vehicle safely and may be involved in a serious
accident.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or uneven tire
pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified in the Owner's Manual for this
vehicle. Always maintain proper tire pressure as described on the decal and
in the Owner's Manual. See pages 5 and 100.
19
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SAFETY
Operator Safety
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle
resulting in serious injury or death. Always remove the ignition key when the
vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer inspect the
entire vehicle for possible damage, including (but not limited to) brakes,
throttle and steering systems.
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the
exhaust system. Use caution when traveling through tall grass, especially dry
grass.
20
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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.
21
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FEATURES AND CONTROLS
Component Locations
Some Polaris vehicles are equipped with special features such as the cab
frame. Not all models come with all features. Refer to the specifications
section beginning on page 100.
Cab Frame
(if Equipped)
Steering
Wheel
Hip Bar
Console
Storage Box
(under driver’s seat)
Seat
Battery
(under hood)
Cargo Box
Seat Belt
Fuel Tank Cap
22
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FEATURES AND CONTROLS
Component Locations
Headlights
Radiator
(if equipped)
Hood
Hold-Down
Strap
Front Bumper/Brush Guard
23
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FEATURES AND CONTROLS
Component Locations
Tailgate
Latch Release
Taillights
Taillights
Tailgate
Air Box
CV Boot/Rear Caliper
Muffler
Receiver Hitch
(Spark Arrestor)
24
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FEATURES AND CONTROLS
Component Locations
Indicator Lights
The indicator light panel is located on the console. See page 28.
Low Gear
(if equipped)
Reverse
Gear
Brakes
High
Temperature
High
Gear
Neutral
Gear
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 pages 44-47.
Auxiliary Outlet
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.
Auxiliary Outlet
25
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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.
Fuel Cap/Fuel Gauge
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
empty mark, refuel at the earliest
opportunity.
Fuel
Cap
When refueling, always use either
leaded or unleaded gasoline with a
minimum pump octane number of 87
R+ M/2 octane. Do not use E-85 fuel.
26
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FEATURES AND CONTROLS
WARNING
Seat Belts
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 may ride in the
RANGER.
The RANGER is equipped with lap-
style seat belts for the operator and
passenger.
Seat
Belt
To wear the seat belt properly, follow
this procedure:
1. Place the belt across your lap as
low on your hips as possible.
Make sure 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.
4. To release the seat belt, press the square red button in the buckle's
center.
27
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FEATURES AND CONTROLS
Console
Indicator
Lights
Gear
Selector
(Shifter)
AWD/Differential
Switch
Light
Switch
Cup
Holder
Cup
Holder
Ignition
Switch
Storage
Box
12V
Accessory
Outlet
Storage
Compartment
(with lid)
Storage
Tray
28
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FEATURES AND CONTROLS
Gear Selector
H: High Gear
L: Low Gear
N: Neutral
H
L
Gear
Selector
R: Reverse
N
NOTE: Low gear is the primary
driving range for the
R
RANGER. High gear is
intended for use on hard-
packed surfaces with light
loads.
To change gears, stop the vehicle,
and with the engine idling, move
the lever to the desired gear. Do
not attempt to shift gears with
engine speed above idle or while
the vehicle is moving.
NOTE: Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting
problems.
CAUTION
Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the vehicle is
stationary and the engine is at idle.
29
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FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow or stop the vehicle. Apply the brakes
while starting the engine.
Throttle Pedal
Push the pedal down to
Brake
Pedal
increase engine speed.
Spring pressure returns
the pedal to the rest
position when released.
Always check that the
throttle pedal returns
normally before start-
ing the engine. Make
sure there's adequate
throttle pedal freeplay.
See page 78 for throttle
pedal adjustment proce-
dures.
Park Brake
Release
Park Brake
Pedal
Throttle
Pedal
Park Brake Pedal
Engage the park brake when parking the vehicle to help prevent the
vehicle from rolling. To engage the park brake, apply the brakes, then
push the park brake pedal down firmly and fully with your foot.
Park Brake Release
Always apply the service brakes before releasing the park brake. To
release the park brake, pull the park brake release handle. Make sure the
park brake pedal is functioning properly before each operation.
30
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FEATURES AND CONTROLS
Switches
Light
High
AWD
2WD
OFF
Switch
Beam
AWD/
Differential
Switch
Low
Beam
OFF
Ignition Switch
Ignition Switch
The ignition switch is a three-position, key-operated switch. The key
can be removed from the switch when it is in the OFF position.
OFF
ON
The engine is off. Electrical circuits are off, except Acc, 12V.
Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter.
The key returns to the ON position when released.
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle
resulting in serious injury or death. Always remove the ignition key when the
vehicle is not in use
Light Switch
The ignition switch key must be in the ON/RUN position to operate the
headlights. The light switch has three positions: high beam, low beam
and off.
AWD/Differential Lock Switch
The AWD/Differential Switch has three positions: All Wheel Drive
(AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/turf
mode).
Press the top of the rocker switch to engage All Wheel Drive (AWD).
See page 50 for AWD operating instructions.
Move the rocker switch to the center position to lock the differential and
operate in two wheel drive (2WD). See page 49 for Differential Lock
operating instructions.
Press the bottom of the switch to unlock the differential and allow the
rear drive wheels to operate independently (1WD). This mode of opera-
tion is well suited to turf driving or when active traction is not needed.
31
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OPERATION
Vehicle Break-In Period
The break-in period for your new Polaris RANGER is the first twenty
hours of operation, or the time it takes to use the first two tanks full of
gasoline. No single action on your part is as important as a proper break-
in period. Careful treatment of a new engine will result in more efficient
performance and longer life for the engine. Perform the following pro-
cedures carefully.
CAUTION
Excessive heat build-up during the first three hours of operation will damage
close-fitted engine parts. Do not operate at full throttle or high speeds for
extended periods during the first three hours of use.
Use of any oils other than those recommended by Polaris may cause serious
engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil
for your 4-cycle engine.
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page
21.
2. Check the oil level. See page 59. Add the recommended oil as
needed to maintain the oil level in the normal (safe) operating
range.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 33.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 25
hours.
32
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OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury or death
could result. Always inspect the vehicle before each use to ensure it's in
proper operating condition.
Item
Remarks
Page
Brake system/pedal travel
Ensure proper operation
30
79
Brake fluid
Front suspension
Rear suspension
Steering
Ensure proper level
79
57
57
81
Inspect, lubricate if necessary
Inspect, lubricate if necessary
Ensure free operation
Tires
Inspect condition and pressure
5
83
Wheels/fasteners
Inspect, ensure fastener tightness
83
-
Frame nuts, bolts, fasteners Inspect, ensure tightness
Fuel and oil
Ensure proper levels
26
59
Coolant level
Ensure proper level
70
71
Coolant hoses
Throttle
Inspect for leaks
-
Ensure proper operation
Ensure operation
77
25
74
74
85
Indicator lights/switches
Air filter, pre-filter
Air box sediment tube
Headlamp
Inspect, clean
Drain deposits whenever visible
Check operation, apply Polaris dielec-
tric grease when lamp is replaced
Brake light/tail lamp
Check operation, apply Polaris dielec-
tric grease when lamp is replaced
87
33
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OPERATION
Starting Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
1. Sit in the driver's seat and fasten the seat belt.
2. Engage the park brake.
3. Shift the transmission to neutral.
4. Apply the brakes.
NOTE: Do not press the throttle pedal while starting the engine.
5. Turn the ignition key past the ON/RUN position to START. Engage
the starter for a maximum of five seconds. Release the key when the
engine starts.
6. If the engine does not start within five seconds, release the ignition
switch and wait five seconds. Repeat steps 5 and 6 until the engine
starts.
7. Vary the engine RPM slightly with the throttle to aid in warm up
until the engine idles smoothly.
CAUTION
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
34
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OPERATION
Stopping the Engine
1. Release the throttle pedal completely and brake to a complete stop.
2. Turn the engine off.
3. Engage the park brake.
WARNING
A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine.
Braking
1. Release the throttle pedal completely.
2. Press on the brake pedal evenly and firmly.
NOTE: Practice starting and stopping (using the brakes) until you're familiar
with the controls.
NOTE: When the throttle pedal is released completely and the engine speed
drops near an idle, the vehicle has no engine braking.
WARNING
Failure to allow for increased braking distance when hauling cargo or towing
a trailer may result in accident and injury. Always slow down and allow
additional braking distance when towing or hauling cargo.
35
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OPERATION
Driving Safely
Driving Procedure
1. Sit in the driver's seat and fasten the seat belt.
2. After starting the engine and allowing it to warm up, apply the ser-
vice brakes, and shift the transmission into gear.
3. Check your surroundings and determine your path of travel.
4. Release the park brake.
5. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.
6. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
NOTE: Low gear is the primary range for operating the RANGER. High gear is
intended for use on hard-packed surfaces with light loads.
36
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OPERATION
Driving Safely
Driving On Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose gravel, or
ice, be alert for the possibility of skidding and sliding. Under these con-
ditions, follow these precautions:
1. Slow down when entering slippery areas.
2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
3. Correct a skid by turning the steering wheel in the direction of the
skid.
4. Drive with AWD engaged (if equipped) to assist in controlling the
vehicle..
CAUTION
Severe damage to the drive train may occur if the AWD is engaged while the
wheels are spinning. Always allow the wheels to stop spinning before
engaging AWD.
WARNING
Failure to exercise care when operating on slippery surfaces can result in
loss of tire traction and cause loss of control, accident, and serious injury or
death.
Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution when operating on slippery
surfaces.
37
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OPERATION
Driving Safely
Driving Uphill
Whenever traveling
uphill, follow these
precautions:
1. Always travel
straight uphill.
2. Avoid steep hills
(15° maximum).
3. Keep both feet on
the floor.
4. Proceed at a
steady rate of
speed and throttle
opening.
15° maximum
WARNING
Climbing hills improperly can cause loss of control or vehicle overturn.
Always check the terrain carefully before climbing a hill.
Braking and handling are greatly affected when operating in hilly terrain.
Improper procedure could cause loss of control or overturn and result in
serious injury or death.
Avoid climbing steep hills (15° maximum).
Use extreme caution when operating on hills, and follow proper operating
procedures outlined in the owner's manual.
Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly.
Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.
38
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OPERATION
Driving Safely
Driving on a Sidehill (Sidehilling)
WARNING
Crossing hillsides or turning on hills can result in loss of control or vehicle
overturn, resulting in severe injury or death. Avoid crossing the side of a hill
when possible. When unavoidable, exercise extreme caution. Avoid
operating on steep hills (15° maximum).
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Slow down.
3. Apply the brakes slightly to aid in slowing.
WARNING
Traveling downhill improperly could cause loss of control or vehicle overturn.
Always check the terrain carefully before descending a hill.
Never descend a hill at high speed. Excessive speed may result in loss of
vehicle control and lead to serious injury or death. Always operate slowly
when traveling downhill.
Avoid descending a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight downhill when possible.
39
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OPERATION
Driving Safely
Driving Through Water
WARNING
The large tires on your RANGER may cause the vehicle to float in deep or
fast-flowing water, which could result in loss of control and lead to serious
injury or death. Never cross deep or fast-flowing water with your RANGER.
Your Polaris RANGER
can operate through
water up to a maximum
recommended depth
equal to the floor-
boards. Follow these
procedures when oper-
ating through water:
1. Always determine
water depths and
current before
entering.
2. Choose a crossing
Floorboard
where both banks
have gradual
inclines.
3. Proceed slowly, avoiding rocks and obstacles.
4. After leaving water, always dry the brakes by applying light pres-
sure to the pedal repeatedly until braking action is normal.
NOTE: After running your vehicle in water, it's critical that you perform the ser-
vices outlined in the Periodic Maintenance Chart beginning on page
52. Give special attention to engine oil, transmission oil, front and rear
gearcases, and all grease fittings.
CAUTION
Immersion can result in major damage if the vehicle isn't serviced correctly
and promptly. After immersion, always take the vehicle to your dealer service.
Do not start the engine!
If it's impossible to bring the vehicle to your dealer before starting the engine,
perform the service outlined on page 73, and take the vehicle to your dealer
at the first opportunity.
40
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OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you're traveling on.
Watch for hazards such as logs, rocks and low hanging branches.
WARNING
Severe injury or death can result if your vehicle suddenly comes in contact
with a hidden obstacle. Not all obstacles are immediately visible. Reduce
speed and travel with caution in unfamiliar terrain.
41
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OPERATION
Driving Safely
Driving in Reverse
Follow these guidelines when operating in reverse:
1. Back slowly.
2. Apply the brakes lightly for stopping.
3. Avoid turning at sharp angles.
4. Always avoid backing downhill.
5. Never open the throttle suddenly while backing.
6. Always inspect left and right fields of vision before backing.
WARNING
Failure to use caution when operating in reverse can result in serious injury
or death. Before shifting into reverse, always check for obstacles or people
behind the vehicle and follow the reverse operation procedures outlined in
this manual. Always back slowly.
42
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OPERATION
Driving Safely
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Place the transmission in gear.
2. Engage the park brake.
3. Turn the engine off.
4. Block the rear wheels on the downhill side.
WARNING
A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine. Always block the downhill
side of the wheels if leaving the vehicle on a hill, or park the vehicle in a
sidehill position instead.
Operating the vehicle while the park brake is engaged could cause loss of
control and result in serious injury or death. Always disengage the park brake
before operating the vehicle.
43
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OPERATION
Driving Safely
Hauling Cargo
WARNING
Hauling cargo improperly can alter vehicle handling and may cause loss of
control or brake instability, which can result in serious injury or death. Always
follow these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
Always load the cargo box with the load as far forward and as low as
possible.
When operating over rough or hilly terrain, reduce speed and cargo to
maintain stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the
vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the
rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing
loads in rough terrain, while cornering, or while ascending or descending a
hill.
44
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OPERATION
Driving Safely
Hauling Cargo
The RANGER has been designed to carry or tow specific capacities.
Always read and understand the load distribution warnings listed on the
warning labels. Never exceed the following capacities.
Model
Maximum Capacities
(Level Ground)
Cargo Box
RANGER 4X4 500 EFI
1500 lbs. (681 kg)
1000 lbs. (454 kg)
WARNING
Driving with
passengers in the
cargo box can result
in severe injury or
death.
Never allow
passengers to ride
in the cargo box.
Passengers must
always ride in the
cab with seat belts
fastened securely.
45
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OPERATION
Driving Safely
Dumping the Cargo Box
WARNING
Operating the vehicle while the cargo box is raised could result in severe
injury. The box could close unexpectedly and cause injury to the driver or
passenger. The rear tires will also catch the rear of a raised box, damaging
the vehicle and creating hazardous driving conditions. Never operate this
vehicle with the cargo box in the raised position.
1. Select a level site to
dump the cargo box.
Do not attempt to
dump or unload the
vehicle while parked
on an incline.
2. Engage the park
brake.
3. Dismount the vehicle.
4. Ensure that the cargo
Release Lever
is positioned evenly or
toward the front of the
cargo box.
5. Release the tailgate by pulling up on the tailgate latch.
6. Stand clear and pull up on the cargo box release lever.
7. Lift the front of the cargo box to dump the cargo.
8. Lower the cargo box and push down securely to latch.
WARNING
If the weight distribution on the box is located toward the rear of the box when
the release lever is pulled forward, the box may dump unexpectedly and
cause serious injury to the operator or bystanders.
Never operate the dump lever without ensuring that the load is positioned
evenly or at the front of the box.
46
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OPERATION
Driving Safely
Towing Loads
WARNING
Towing improperly can alter vehicle handling and may cause loss of control
or brake instability, which can result in serious injury or death. Always follow
these precautions when towing:
Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.
Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See
page 44. Towing a trailer increases braking distance.
Do not tow more than the recommended weight for the vehicle. See the
towing capacity chart below and the specifications charts beginning on page
100.
Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any
other location or you may lose control of the vehicle.
Never tow a trailer on a grade steeper than 15°.
Model
Total Towed
Load Weight
(Level Ground)
Total Towed
Load Weight
(15° grade)
Total Hitch Maximum
Vertical
Weight
Towing
Speed
RANGER 4X4
1500 lbs.
(681 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 mph
(16 kph)
500 EFI
Belt Life
To extend belt life, use the lowest gear possible when hauling or towing
heavy cargo.
47
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OPERATION
Driving Safely
Parking the Vehicle
WARNING
A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine.
1. Stop the vehicle on a level surface.
2. Turn the engine off.
3. Engage the park brake.
4. Remove the ignition switch key to prevent unauthorized use.
WARNING
Gasoline is extremely flammable and can be explosive under certain
conditions. When parking inside a garage or other structure, be sure that the
structure is well ventilated and that the vehicle is not close to any source of
flame or sparks, including any appliance with pilot lights.
48
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OPERATION
Differential Operation Modes
The 4X4 rear axle is equipped with a lockable differential that allows
the operator to choose between an open differential or a closed differen-
tial.
AWD
Press the top of the rocker switch to
engage All Wheel Drive (AWD). When
in AWD, the rear wheels rotate at the
same speed. The front wheels also rotate
at the same speed. See page 50 for AWD
operating instructions.
2WD/Rear Differential Locked
Move the rocker switch to the center
position to lock the differential and oper-
ate in two wheel drive (2WD). Locking
the differential in slippery or low traction
conditions helps improve traction. When
the rear differential is locked, both rear
wheels rotate at the same speed.
OFF/Differential Unlocked
Press the bottom of the switch to unlock the differential and allow the
rear drive wheels to operate independently (1WD). When the rear differ-
ential is unlocked, the rear wheels can rotate at different speeds. Unlock
the differential to make maneuvering easier and minimize damage to
turf.
CAUTION
Damage to the differential can occur if it is engaged while the vehicle is
traveling at high speeds or while the rear wheels are spinning. Slow the
vehicle to nearly stopped before engaging the differential.
49
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OPERATION
All Wheel Drive (AWD)
The illuminated amber AWD
switch indicates that the vehi-
cle is in AWD.
AWD Switch
When the AWD switch is on,
the front gearcase will auto-
matically engage any time the
rear wheels lose traction.
When the rear wheels regain
traction, the front gearcase will
automatically disengage.
There is no limit to the length of time the vehicle may remain in AWD.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the front gearcase is moving, it will not disengage until the rear
wheels regain traction.
Engage the AWD before getting into conditions where front wheel drive
may be needed. If the rear wheels are spinning, release the throttle
before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning may cause severe drive
shaft and clutch damage. Always switch to AWD while the rear wheels have
traction or are at rest.
Disengaging AWD
Under certain conditions, it may be possible for the front gearcase to
remain locked unnecessarily. This condition causes increased steering
effort and some vehicle speed restriction. If the front gearcase remains
locked after following these instructions, return the vehicle to your
dealer for service.
1. Stop the vehicle.
2. Operate in reverse for at least 10 feet.
3. Stop completely.
4. Shift into low gear and drive forward.
50
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EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your Polaris vehicle has a spark arrestor that was tested and qualified to
be in accordance with the USDA Forest Service Standard 5100-1C. Fed-
eral law requires that this spark arrestor be installed and functional when
the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. Is regulated
by 43 CFR 8343. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com-
ponents are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on either the recoil cover or stator hous-
ing.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with European directives 97/24/EC and 89/336/
EEC.
51
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MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
Record maintenance and service in the Maintenance Log beginning on
page 116.
NOTE: Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have
a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately ten
(10) miles per hour. Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
52
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MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X
Perform these operations more often for vehicles subjected to
severe use.
E
Emission Control System Service - 4 Cycle (California)
Q
Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a Q could result in
component failure and lead to serious injury or death. Have an authorized
Polaris dealer perform these services.
53
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MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Q
Steering
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
-
-
-
-
-
Make adjustments as need
ed. See Pre-Ride Checklist
on page 33.
X Front suspension
X Rear suspension
Tires
X Brake fluid level
X Brake pedal travel
Brake system
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Daily
-
-
-
-
-
Wheels/fasteners
Frame fasteners
X Engine oil level
X Air filter, pre-filter
E
Inspect; clean often; replace
as needed
X Air box sediment
-
Daily
Daily
-
-
-
-
-
Drain deposits when visible
E tube
Coolant
(if applicable)
-
Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
-
Daily
Check operation; apply
dielectric grease if replacing
X Air filter,
E main element
-
Weekly
Monthly
Inspect; replace as needed
X Brake pad wear
10 H
20 H
Inspect periodically
Q
Battery
Monthly
Monthly
-
-
Check terminals; clean; test
Inspect level; change yearly
X Front Gearcase Oil 25 H
(if equipped)
X Middle Gearcase
25 H
25 H
25 H
Monthly
Monthly
Monthly
-
-
-
Inspect level; change yearly
Inspect level; change yearly
Inspect level; change yearly
Oil (if equipped)
X Rear gearcase oil
(if equipped)
X Transmission oil
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
54
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MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
X Engine breather
25 H
25 H
50 H
Monthly
1 M
-
-
-
Inspect; replace if necessary
E filter (if equipped)
X Engine oil change
Perform a break-in oil change
at one month
(break-in)
X General
3 M
Lubricate all fittings, pivots,
cables, etc.
lubrication
Shift Linkage
50 H
50H
6 M
6 M
6 M
6 M
6 M
-
-
-
-
-
Inspect, lubricate, adjust
Lubricate
Q
Steering
X Front Suspension
50 H
50 H
50 H
Lubricate
X Rear Suspension
Lubricate
Q
E
Throttle cable
Inspect; adjust; lubricate;
replace if necessary
E Throttle body air
50 H
50 H
50 H
6 M
6 M
6 M
-
-
-
Inspect duct for proper seal-
ing/air leaks
intake ducts/flange
Drive belt
Inspect; adjust; replace as
needed
Cooling system
(if applicable)
Inspect coolant strength
seasonally; pressure test
system yearly
X Engine oil change 100 H
X Oil filter change 100 H
6 M
6 M
-
-
Perform a break-in oil change
at one month
Replace with oil change
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
55
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MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Q
E
Fuel system
Fuel filter
100 H
12 M
-
Check for leaks at tank cap,
lines, fuel valve, filter, pump,
throttle body; re
Q
E
100 H
100 H
12 M
12 M
-
-
Replace yearly
X Radiator
(in applicable)
Inspect; clean external
surfaces
X Cooling Hoses
100 H
100 H
100 H
12 M
12 M
12 M
-
-
-
Inspect for leaks
Inspect
X Engine mounts
Exhaust muffler/
pipe
Inspect
X Spark plug
100 H
12M
-
Inspect; replace as needed
Inspect
E
Q
Ignition timing
100 H
100 H
12 M
12 M
-
-
X Wiring
Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Q
Clutches (drive
100 H
100 H
12 M
12 M
-
-
Inspect; clean; replace worn
parts
and driven)
Q
Front wheel
bearings
Inspect; replace as needed
Q
Brake fluid
200 H
300 H
24 M
36 M
-
-
Change every two years
Clean out
Spark arrestor
Idle speed
-
Adjust as needed
Q
Toe adjustment
-
-
-
Inspect periodically; adjust
when parts are replaced
Q
X
Auxiliary brake (if
equipped)
Inspect daily; adjust as
needed
Headlight aim
Adjust as needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
56
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MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 52, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item
Lube
Method
Engine Oil
Polaris Premium 4 Synthetic See page 59.
0W40
Brake Fluid
DOT 3 or DOT 4
See page 79.
See page 63.
Main Gearcase Oil
(Transmission)
Premium AGL Synthetic
Gearcase Lube
Front Gearcase Oil
Rear Gearcase Oil
Prop Shaft U-joints
Front Prop Shaft Yoke
Ball Joint
Premium Demand Drive Hub See page 65.
Fluid
Premium ATV Angle Drive
Fluid
See page 66.
Polaris Premium U-Joint
Lube
Locate fittings and grease. See
above.
Polaris Premium U-Joint
Lube
Locate fittings and grease
(3 pumps maximum).
Polaris Premium all Season Locate fitting (back side of
Grease or grease conform- struts), grease with grease gun.
ing to NLGI No. 2
Swing Arm
Bushings
Polaris Premium all Season Locate fittings on swing arm and
Grease or grease conform- grease with grease gun.
ing to NLGI No. 2
.
Prop Shaft U-Joint
57
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MAINTENANCE
Engine Oil
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 52. Always change the
oil filter whenever changing oil.
Premium 4 Synthetic Oil
Polaris Premium 4 All Season Synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high
performance, multi-viscosity oil designed to provide the ultimate in
lubrication performance and protection. See page 102 for the part num-
bers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest possible
temperature range. It resists viscosity and frictional breakdown in ambi-
ent temperatures from -40° F. to 120° F. Its exceptional frictional prop-
erties result in more efficient operation, more power output and lower
fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use in this
engine, use of any API certified "SH" oil is allowable as long as it's 0W-
40. Oil may need to be changed more frequently if Polaris Premium 4 is
not used. Follow the manufacturer's recommendations for ambient tem-
perature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine
damage. We recommend the use of Polaris Premium 4 All Season synthetic
oil or API certified "SH" oil, 0W-40. Never substitute or mix oil brands. Use
only 0W-40.
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine oil
will cause accelerated wear and may result in engine seizure, accident, and
injury. Always perform the maintenance procedures as outlined in the
Periodic Maintenance Chart.
58
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MAINTENANCE
Engine Oil
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 52. We recommend the use of
Polaris Premium 4 All Season Synthetic engine oil.
Oil Check
The oil tank is located under
the seat.
1. Position the vehicle on a
level surface.
2. Apply the brakes. Start the
engine and allow it to idle
for 20-30 seconds. Stop the
engine.
3. Remove the seat. See page
26.
4. Remove the dipstick. Wipe
it dry with a clean cloth.
Safe Range
5. Reinstall the dipstick.
Screw it in completely.
NOTE: The dipstick must be
screwed in completely to
Full
Add
keep the angle and
depth of the stick consis-
tent.
Remove the dipstick. Make sure that the oil level is between the full and
add marks. Add oil if necessary. Do not overfill.
NOTE: A rising oil level between checks in cool weather driving can indicate
moisture collecting in the oil reservoir. If the oil level is above the full
mark, change the oil.
59
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MAINTENANCE
Engine Oil
Oil and Filter Change
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to come into
contact with skin.
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 52. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level
surface.
2. Run the engine for two to
three minutes until warm.
Stop the engine.
Drain
Plug
3. Clean the area around the
drain plug.
4. Place a drain pan beneath oil
tank.
Screen
Fitting
5. Remove the drain plug.
Allow the oil to drain com-
pletely.
Sealing
Washer
6. Install a new sealing washer
on the drain plug.
NOTE: The sealing surfaces on
drain plug and oil tank
Orientation
Mark
should be clean and free of
burrs, nicks or scratches.
7. Reinstall the drain plug.
Torque to 14 ft. lbs. (19 Nm).
8. Disconnect the lower oil delivery hose and remove the screen fitting
from the oil tank. Clean the fitting.
NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE
seal tape.
9. Reinstall the screen fitting and rotate the fitting clockwise a mini-
mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-
ting until the nipple of the fitting aligns with the mark on the tank.
NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.
(34 Nm).
60
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MAINTENANCE
Engine Oil
Oil and Filter Change
10. Reattach the oil line.
11. Place shop towels beneath
the oil filter. Using an oil fil-
ter wrench, turn the filter
counterclockwise to remove
it.
12. Using a clean dry cloth,
clean the filter sealing sur-
face on the crankcase.
13. Lubricate the gasket on the
new filter with a film of new
engine oil. Make sure the
gasket is in good condition.
Make sure the gasket from
the old filter is not still on
the engine.
Oil Filter
14. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn and additional 1/2 turn.
15. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank-
case.
NOTE: The sealing surfaces on the drain plug and crankcase should be clean
and free of burrs, nicks or scratches.
16. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
17. Remove the dipstick and fill the tank with two quarts (1.9 l) of the
recommended oil.
18. Place the gear selector in neutral and engage the parking brake.
19. Prime the oil pump using the procedure on page 62. Then stop
the engine and inspect for leaks.
20. Check the oil level on the dipstick. Add oil as necessary to bring the
level to the upper mark on the dipstick.
21. Dispose of used filter and oil properly.
61
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MAINTENANCE
Engine Oil
Oil and Filter Change
Oil Pump Priming
This priming procedure must be
performed whenever the oil hose
connection between the oil tank and
pump inlet has been disconnected.
Tank
2"
(5 cm)
1. Clamp or pinch off the vent line
approximately 2" (5 cm) from
the oil tank, between the end of
the oil tank vent fitting and the
vent line's pressure relief slit.
Clamp
Pressure
Relief Slit
2. Start the engine. Allow it to idle
for 10-20 seconds.
3. Remove the vent line clamp. If the line is bled properly, you should
hear a rush of air, indicating that the line is properly primed and
ready for operation.
NOTE: If you do not hear air, the line has not bled. Repeat the priming proce-
dure.
62
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MAINTENANCE
Gearcases
Gearcase Specification Chart
Gearcase
Lubricant
Capacity
Fill Plug
Torque
Drain Plug
Torque
Main Gearcase
(Transmission)
Premium AGL
Synthetic
Gearcase Lube
15.2 oz.
(450 ml)
14 ft. lbs.
(19.4 Nm)
14 ft. lbs.
(19.4 Nm)
Front Gearcase
Rear Gearcase
Premium Demand
Drive Hub Fluid
5 oz.
8-10 ft. lbs.
11 ft. lbs.
(15 Nm)
(150 ml)
(11-13.6 Nm
Premium ATV
Angle Drive Fluid
18 oz.
(532 ml)
40-50 ft. lbs.
(54-68 Nm
30-45 in. lbs.
(3-5 Nm)
Transmission (Main Gearcase)
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 52. Maintain the
oil level even with the bottom of the fill plug hole.
Refer to the Gearcase Specifications Chart for recommended lubricants,
capacities and torque specifications. See page 102 for the part numbers
of Polaris products.
Oil Check
The fill plug is located at the rear
of the vehicle.
1. Position the vehicle on a level
surface.
2. Remove the fill plug.
3. Check the oil level.
4. Add the recommended oil as
needed.
5. Reinstall the fill plug. Torque
to specification.
Fill Plug
63
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MAINTENANCE
Gearcases
Transmission (Main Gearcase)
Oil Change
The drain plug is located on the
bottom of the transmission.
Access the drain plug through the
drain hole in the skid plate.
1. Remove the fill plug.
2. Place a drain pan under the
drain plug.
3. Remove the drain plug. Drain
the oil.
4. Wipe the magnetic end of the
drain plug clean to remove
accumulated metallic filings.
5. After the oil has drained
completely, install a new
sealing washer.
Drain Plug
NOTE: Refer to the Gearcase Specifications Chart on page 63 for recom-
mended lubricants, capacities and torque specifications.
6. Reinstall the drain plug. Torque to specification.
7. Add the recommended oil as needed. Do not overfill.
8. Reinstall the fill plug. Torque to specification.
9. Check for leaks.
10. Dispose of used oil properly.
64
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MAINTENANCE
Gearcases
Front Gearcase
Always check and change the front gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 52. Maintain the
oil level even with the bottom thread of the fill plug hole.
Refer to the Gearcase Specifications Chart on page 63 for recommended
lubricants, capacities and torque specifications. See page 102 for the
part numbers of Polaris products.
Oil Check
The front gearcase fill plug is located on
the right side of the front gearcase.
1. Position the vehicle on a level surface.
2. Remove the fill plug. Check the oil
level.
3. Add the recommended oil as needed.
4. Reinstall the fill plug. Torque to spec-
ification.
Fill Plug
Oil Change
1. Support the vehicle securely with a
jackstand.
2. Remove the front tire on the driver's
side.
Drain Plug
3. Remove the fill plug.
4. Place a drain pan under the drain plug on the bottom right-hand
side.
5. Remove the drain plug. Drain the oil.
6. Clean the drain plug. Reinstall the drain plug. Torque to specifica-
tion.
7. Add the recommended oil.
8. Reinstall the fill plug. Torque to specification.
9. Check for leaks.
10. Discard used oil properly.
65
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MAINTENANCE
Gearcases
Rear Gearcase
Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 52.
Refer to the Gearcase Specifications Chart on page 63 for recommended
lubricants, capacities and torque specifications. See page 102 for the
part numbers of Polaris lubrication products.
Oil Check
The rear gearcase fill plug is on the driver's side of the rear gearcase.
Maintain the oil level 3/4 of an inch (19 mm) below the bottom thread of
the fill plug hole. Use a light colored non-absorbent measuring instru-
ment (such as a white cable tie) to measure the depth.
1. Position the vehicle on a
Fill Plug
level surface.
2. Remove the fill plug. Check
the oil level.
3. Add the recommended oil
as needed.
4. Reinstall the fill plug.
Torque to specification.
Oil Change
1. Remove the fill plug.
2. Place a drain pan under the
drain plug.
3. Remove the drain plug. Drain
the oil.
4. Clean the drain plug. Reinstall
the drain plug. Torque to
specification.
Drain Plug
5. Add the recommended oil.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
66
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MAINTENANCE
Spark Plugs
CAUTION
Using non-recommended spark plugs can result in serious engine damage.
Always use Polaris-recommended spark plugs. Refer to the specifications
section beginning on page 100.
Spark Plug Gap/Torque
Model
Electrode Gap
New Plug
Torque
Used Plug
Torque
RANGER 4X4
.036" (.9 mm)
9-11 ft. lbs.
(12-15 Nm)
9-11 ft. lbs.
(12-15 Nm)
500 EFI
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. See page 68.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
67
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MAINTENANCE
Spark Plugs
Spark Plug Condition
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi-
cates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil or incorrect throttle body adjust-
ments.
Spark Plug Removal and Replacement
1. Remove the seat to access the engine compartment.
2. Remove the spark plug cap. Using the spark plug wrench provided
in the tool kit, remove the plug by rotating it counterclockwise.
3. Reverse the procedure for spark plug installation. Torque to specifi-
cation. See page 67.
68
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MAINTENANCE
Cooling System
Operation
The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the overflow bottle, radia-
tor filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
NOTE: Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Observe coolant levels and maintain as
recommended by adding coolant to the overflow bottle.
Adding or Changing Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. Polaris recommends the
use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of
high quality aluminum compatible anti-freeze/coolant and distilled
water. Polaris Premium 60/40 is already premixed and ready to use. Do
not dilute with water. See page 102 for the part numbers of Polaris prod-
ucts.
NOTE: Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.
69
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MAINTENANCE
Cooling System
Radiator and Cooling Fan
Always check and clean the screen and radiator fins at the intervals out-
lined in the Periodic Maintenance Chart beginning on page 52. Do not
obstruct or deflect air flow through the radiator by installing unautho-
rized accessories in front of the radiator or behind the cooling fan. Inter-
ference with the radiator air flow can lead to overheating and
consequent engine damage.
CAUTION
Washing the vehicle with a high-pressure hose could damage the radiator
fins and impair the radiator's effectiveness. Using a high-pressure system is
not recommended.
Coolant Level
Always check and change the coolant at the intervals outlined in the
Periodic Maintenance Chart beginning on page 52. Maintain the coolant
level between the minimum and maximum marks on the bottle (when
the fluid is cool).
The overflow bottle is located in front of
the right front wheel.
1. Position the vehicle on a level surface.
2. View the coolant level in the overflow
bottle.
3. If the coolant level is below the safe
Overflow
Bottle
operating range, lift the hood and
locate the overflow bottle lid. Remove
the lid and use a funnel to add coolant
through the filler opening. Reinstall
the cap.
NOTE: If coolant must be added often, or if the overflow bottle runs completely
dry, there may be a leak in the system. Have the cooling system
inspected by your Polaris dealer.
70
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MAINTENANCE
Cooling System
Radiator Coolant Level
Always check and clean the screen and radiator fins at the intervals out-
lined in the Periodic Maintenance Chart beginning on page 52. Do not
obstruct or deflect air flow through the radiator by installing unautho-
rized accessories in front of the radiator or behind the cooling fan. Inter-
ference with the radiator air flow can lead to overheating and
consequentially, engine damage.
WARNING
Escaping steam can cause severe burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.
1. Lift the hood.
2. Slowly remove the radi-
Radiator
Cap
ator cap.
3. View the coolant level
through the opening.
4. Use a funnel and slowly
add coolant as needed.
NOTE: This procedure is
required only if the
cooling system has
been drained for
maintenance and/or
repair. But if the over-
flow bottle has run
dry, the level in the
radiator should also
be inspected.
NOTE: Use of a non-standard pressure cap will not allow the recovery system
to function properly. See your dealer for the correct replacement part.
71
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MAINTENANCE
Polaris Variable Transmission (PVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe
injury or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has
been precision balanced. Any modification will cause the system to be out of
balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted
to ensure the safety of this product. However, as the owner, you have the
following responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer
as outlined in the owner's manual.
• This PVT system is intended for use on Polaris products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
When To Use Low Range vs. High Range
Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).
Condition
Range to Use
Operating at speeds less than 7 MPH (11 km/h)
Towing heavy loads
Low
Low
Low
High
Operating in rough terrain (swamps, mountains, etc.)
Operating at speeds greater than 7 MPH (11 km/h)
72
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MAINTENANCE
PVT System
PVT Drying
There may be some instances when water is ingested into the PVT sys-
tem. Use the following instructions to dry it out before operating.
1. Loosen the bottom screws that secure the clutch cover. Allow the
water to drain. Tighten the screws.
2. Apply the brakes. Start the engine. Engage the park brake. Shift the
transmission to neutral.
3. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
4. Allow the engine RPM to settle to idle speed. Apply the service
brakes. Release the park brake and shift the transmission to the low-
est available range.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Take the vehicle to your dealer for service as soon as possible.
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to your dealer before
starting the engine.
If it's impossible to take your RANGER to a dealer before starting it, fol-
low the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the
footrests.Dry any water present in the air box. Filter replacement is
required if water is present.
2. Thoroughly dry the air pre-cleaner located under the hood.
3. Remove the spark plugs. Turn the engine over several times using
the electric start.
4. Dry the spark plugs and reinstall, or replace with new plugs.
NOTE: Attempt to start the engine. If necessary, repeat the drying procedure.
5. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE: If water has been ingested into the PVT follow the procedure on page
73 for drying.
73
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MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 52.
1. Lift the cargo box to
access the air box.
2. Remove the air box
cover and inspect the
gasket. It should adhere
tightly to the cover and
seal all the way around.
Air Filter
3. Remove the air filter.
4. Do not attempt to clean
the main element.
Install a new air filter.
NOTE: Apply a small amount
of general purpose
grease to the sealing
edges of the filter
before installing.
5. Inspect the air box for oil or water deposits. If present, drain them
into a suitable container.
NOTE: Service the air filter more frequently if the vehicle is operated in wet
conditions or at high throttle openings for extended periods.
Fuel Filter
Your Polaris vehicle is equipped with an in-line fuel filter. Have your
dealer replace it after every 100 hours of operation. Do not attempt to
clean the fuel filter.
74
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MAINTENANCE
Filter Systems
Breather Filter and Hoses
1. Lift the cargo box and
locate the air box.
Breather Line
Breather Filter
2. Follow the right-hand
breather line out the
side of the air box and
locate the filter.
3. Remove and inspect the
filter for debris. Blow
gently through the filter
in the direction of the
arrow to check for
clogging. Replace as
needed.
4. Check hoses for cracks,
deterioration, abrasion,
or leaks. Replace as
needed.
5. Reinstall the filter with the arrow pointing toward the engine.
Secure the clamps.
CAUTION
Operation of the vehicle without a breather filter can cause engine damage.
Always reinstall the breather filter after removing it for service.
75
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MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark arrestor
could result in serious injury or death.
Do not perform service on the spark arrestor while the system is hot. Exhaust
system temperatures can reach 1000° F. Allow components to cool
sufficiently before proceeding.
Remove any combustible materials from the area.
Wear eye protection and gloves.
Do not stand behind or in front of the vehicle while purging.
Never run the engine in an enclosed area. Exhaust contains poisonous
carbon monoxide gas that can cause loss of consciousness or death in a
very short time.
Never go under the vehicle while it's inclined.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe.
1. Remove the arrestor clean-out
plugs located on the bottom of
the muffler.
2. Shift the transmission to neutral.
Apply the brakes. Start the
engine.
3. Purge accumulated carbon from
the system by momentarily rev-
ving the engine several times.
Exhaust
Outlet
Clean-Out
Plugs
4. If carbon is expelled, cover or
plug the exhaust outlet and rap
on the pipe around the clean-out
plugs while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot higher than the front. Engage the park brake.
Block the wheels. Make sure the transmission is in neutral and
repeat steps 3 and 4 until no more particles are expelled when the
engine is revved.
6. Stop the engine. Allow the arrestor to cool.
7. Reinstall the arrestor plugs and remove the outlet cover or plug.
76
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MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result
in an accident and lead to serious injury or death if the throttle pedal sticks
during operation.
Always check the pedal for free movement and return before starting the
engine and occasionally during operation. Never start or operate this vehicle
if it has a sticking or improperly operating throttle pedal. Immediately contact
your dealer for service if throttle problems arise.
Throttle Freeplay
If the throttle pedal has excessive
play due to cable stretch or mis-
adjustment, it will cause a delay
in throttle response, especially at
low engine speed. The throttle
may also not open fully. If the
throttle pedal has no freeplay, the
throttle may be hard to control,
and the idle speed may be erratic.
Park
Brake
Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 52. Adjust the
freeplay if necessary.
Throttle
Pedal
Throttle Freeplay Inspection
1. Engage the park brake. Shift the transmission to neutral.
2. Apply the brakes. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.6-
3.2 mm).
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MAINTENANCE
Throttle System
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your Polaris dealer for adjustment.
Throttle Freeplay Adjustment
1. Remove the seat.
2. Locate the throttle cable
adjuster.
3. Squeeze the end of the rub-
ber boot and slide it far
enough to expose the end
of the inline cable adjuster.
Boot
4. Loosen the adjuster lock
nut.
5. Rotate the boot to turn the
adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the throttle
pedal. See page 77.
Lock Nut
Adjuster
NOTE: While adjusting, lightly flip the throttle pedal up and down.
6. Tighten the lock nut.
7. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
Cylinder Head/Cylinder Base Fastener Torque
Have your dealer check the cylinder head and cylinder base fasteners for
proper torque at the first service or after 25 hours.
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MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes. Press down on
the brake pedal to engage the brakes. See page 30.
Brake Fluid
Inspect the brake system rou-
Brake Fluid
Reservoir
tinely. Inspect the level of the
brake fluid before each opera-
tion.
Change the brake fluid every two
years and any time the fluid
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown. See
page 57 for fluid recommenda-
tions.
1. Position the vehicle on a
level surface.
2. View the brake fluid level at
the reservoir under the hood.
The level should be between
the upper (MAX) and lower (MIN) level lines.
3. If the fluid level is lower than the lower level line, add brake fluid to
the upper (MAX) line.
4. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
WARNING
After opening a bottle of brake fluid, always discard any unused portion.
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or severe injury.
79
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MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system for
fluid leaks.
2. Check the brake pedal for
excessive travel or a spongy
feel.
3. Check the friction pads for
wear, damage and looseness.
4. Inspect the brake disc spline
and pad wear surface for
excessive wear.
3/64" (1mm)
5. Change pads when worn to
3/64" (1 mm).
Park Brake Inspection
1. Slowly push the park brake
pedal down with your foot.
2. After 8 to 12 clicks of pedal
travel, check the vehicle for
movement. The vehicle
should not roll while parked.
If the vehicle moves, adjust
the park brake.
Park Brake
Pedal
Park Brake Adjustment
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Loosen or tighten the nuts on the pedal end of the park brake cable
as needed.
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MAINTENANCE
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 52.
1. Position the vehicle on a level surface.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8"-1.0" (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels
rough or "catchy," have the steering system inspected by an autho-
rized Polaris dealer.
Suspension Adjustment
The 4X4 rear suspension may be adjusted to provide a stiffer suspension
if necessary.
1. Remove the top shock mounting bolts from the inside mounting
holes.
2. Reposition the shocks to the outside mounting holes.
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).
Outside Mounting Holes
Inside Mounting Holes
Cam
Rear Spring Adjustment
The rear shock absorber springs are adjusted by rotating the adjustment
cam either clockwise or counterclockwise to increase or decrease spring
tension.
81
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MAINTENANCE
Seat Belts
Inspect all three seat belts for proper operation before each use of the
vehicle.
1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.
2. Push the red button in the middle of the buckle to make sure it
releases freely.
3. Check the belt webbing
for wear, cuts or damage.
If any irregularities are
found, have the seat belt
system checked and/or
replaced by an authorized
Polaris dealer.
The RANGER seat belt is
adjustable and should be
adjusted for both the operator
and passengers before driv-
ing. Although having the belt
at 30° is typical for many peo-
ple, it will not accommodate
all body sizes and shapes.
Make sure the seat belt is
Bolts
adjusted to the lowest possible lap position before riding.
1. To adjust, loosen the bolts.
2. Reposition both the buckle and retractor. Tighten the bolts.
NOTE: The center belt does not self adjust. Before riding, pull on the strap to
secure the belt on the lap of the center passenger.
WARNING
Failure to follow the age recommendations for this vehicle could result in
serious injury or death. No one under the age of 16 may operate this vehicle.
No one under the age of 5 may ride as a passenger in this vehicle.
82
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MAINTENANCE
Tires
WARNING
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. When replacing tires,
always use original equipment size and type.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
1/8" (3 mm)
Axle and Wheel Nut Torque Specifications
Inspect the following items occasionally for tightness, and if they've
been loosened for maintenance service.
Nut Type
Location
Nut Torque
Lug Nut
Front and Rear
90 ft. lbs. (122 Nm)
2-Piece Flange
Nut
Front and Rear
Front
35 ft. lbs. (47 Nm)
70 ft. lbs. (95 Nm)
Spindle Nut
Hub Retaining Nuts
Center and Rear 110 ft. lbs. (150 Nm)
NOTE: Do not lubricate the stud or the lug nut.
83
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MAINTENANCE
Tires
WARNING
Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure that all
nuts are torqued to specification. Do not service axle nuts that have a cotter
pin installed. See your Polaris dealer.
Wheel Removal
1. Stop the engine. Place the transmission in gear. Engage the park
brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the
frame.
4. Remove the wheel nuts and washers. Remove the wheel.
Wheel Installation
1. Place the transmission
in gear.
2. Engage the park
brake.
3. Place the wheel in the
correct position on the
wheel hub. Be sure
the valve stem is
toward the outside
and rotation arrows
on the tire point
toward forward rota-
tion.
4. Attach the wheel nuts and washers and finger tighten.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts to specification. See page 83.
84
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MAINTENANCE
Lights
When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.
WARNING
Poor lighting while driving can result in severe injury or death. Headlight and
taillight lenses become dirty during normal operation. Wash the headlights
frequently to maintain lighting quality.
Hot components can cause serious burns to skin. Do not service the
headlamps until they've cooled sufficiently.
Headlight Lamp Replacement
1. Open the hood.
2. Unplug the headlamp from
the wiring harness. Be sure
to pull on the connector, not
on the wiring.
3. Turn the lamp counter-
clockwise to remove it.
4. Install the new lamp.
NOTE: Make sure the tab on the
lamp locates properly in
the housing.
5. Reinstall the harness
assembly into the headlight
assembly.
Wiring
Harness
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MAINTENANCE
Lights
Headlight Beam Adjustment
25 ft.
(7.6 m)
X
X
8" (20 cm)
1. Place the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Apply the brakes. Start the engine. Turn on the headlights.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed 8" (20 cm) below the mark placed on the
wall in step 2.
NOTE: Include the weight of a rider on the seat while performing this step.
5. If the headlight needs
adjustment, open the hood.
NOTE: The lights are part of the
hood assembly.
6. Turn the adjustment screw
Adjustment
to adjust the beam.
Screw
7. Close the hood and repeat
View of driver’s headlight with hood lifted.
steps 4-6 until the lamp is
properly adjusted.
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MAINTENANCE
Lights
Brake Lights
When the brake pedal is depressed, the console brake light comes on.
Check the brake light before each ride.
1. Turn the ignition switch to the ON position.
2. Depress the brake pedal. The brake light should come on after about
10mm (0.4 in.) of pedal travel. If the light doesn't come on, check
the bulb.
Indicator Lamp Replacement
1. Lift the hood.
Release
2. Reach in behind the console
panel and lift the release to
unplug the light from the
harness.
Tab
3. Using a flathead screwdriver,
press on the tab on the top of
the light to remove the indi-
cator light assembly from the
console panel.
4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4
turn counterclockwise.
5. Grip the lamp with a needle-nose pliers and remove it from the
assembly.
6. Install the new lamp. Using a screwdriver, rotate the lamp 1/4 turn
clockwise to seat it.
7. Snap the assembly back into the console panel. Reconnect the har-
ness.
8. Close the hood.
87
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MAINTENANCE
Battery
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be identi-
fied by its flat covers on the top of the battery. A conventional battery
has six filler caps on the top of the battery.
Conventional Battery
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into the battery.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.
away. Ventilate when charging or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
88
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MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
Battery Removal
1. Open the hood.
Battery
2. On conventional batteries,
remove the battery vent
tube.
3. Disconnect the black (nega-
tive) battery cable first.
4. Disconnect the red (positive)
battery cable last.
5. Lift the battery out of the
vehicle. Be careful not to tip
a conventional battery side-
ways, which could spill elec-
trolyte.
CAUTION
If electrolyte spills, immediately wash it off with a solution of one tablespoon
baking soda and one cup water to prevent damage to the vehicle.
89
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MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the bat-
tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 92 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed bat-
teries do not have a vent tube).
NOTE: The vent tube must be free of obstructions and securely installed.
Route the tube away from the frame and vehicle body to prevent con-
tact with electrolyte.
WARNING
Battery gases could accumulate in an improperly installed vent tube and
cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as
recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.
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MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 92.
NOTE: Battery charge can be maintained by using a Polaris Battery Tender
charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage
period, and will automatically charge the battery if the voltage drops
below a pre-determined point. See page 102 for the part numbers of
Polaris products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the bat-
tery fluid level often. Maintain the
fluid level between the upper and
lower level marks.
Upper
Mark
Lower
Mark
Add only distilled water. Tap water
contains minerals that are harmful
to a battery.
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MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 89.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific grav-
ity to 1.270 or greater.
3. Reinstall the battery. See page 90. Make sure the positive terminal is
toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger,
use the guidelines on the next page for recharging.
92
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MAINTENANCE
Battery
Battery Charging (Sealed Battery)
NOTE: Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
(Using constant current
Voltage
Action
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None, check at 3
mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
3-6 hours
charge given,
check in 3 months
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
Needs charge
Needs charge
5-11 hours
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
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MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your Polaris vehicle clean will not only improve its appearance
but it can also extend the life of various components.
CAUTION
High water pressure may damage components. Polaris recommends
washing the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage
plastic surfaces. Do not allow these types of products to contact the vehicle.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
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MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
NOTE: If warning and safety labels are damaged, contact your Polaris dealer
for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
95
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MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a “like new” appearance for many years.
NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean
chrome wheels more often if they're exposed to salt or other corrosive
elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.
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MAINTENANCE
Cleaning and Storage
Storage Tips
CAUTION
Starting the engine during the storage period will disturb the protective film
created by fogging and damage could occur. Never start the engine during
the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 94.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
Follow the instructions on the container for the recommended
amount.
NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and
removes carbon deposits from pistons, rings, valves and exhaust sys-
tems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 60.
Air Filter / Air Box
Inspect and clean or replace the pre-cleaner and air filter. See page 74.
Clean the air box. Drain the sediment tube.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 52.
• Front and rear gearcase fluid
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 52.
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MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-
tions on the container. Start the engine. Allow it to idle for several
minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Syn-
thetic 0W40 engine oil. To access the plug holes, use a section of
clear 1/4" hose and a small plastic squeeze bottle filled with the pre-
measured amount of oil.
NOTE: Do this carefully! If you miss the plug holes, oil will drain from the spark
plug cavities into the hole at the front of the cylinder head, and appear
to be an oil leak.
3. Reinstall the spark plugs. Torque to specification. See page 67.
4. Apply dielectric grease to the inside of each spark plug cap and rein-
stall the caps onto the plugs.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protec-
tive film of fresh oil.
6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
Battery Maintenance
See pages 91-93 for storage and charging procedures.
Storage Area/Covers
Be sure the storage area is well ventilated. Cover the vehicle with a gen-
uine Polaris cover.
NOTE: Do not use plastic or coated materials. They do not allow enough ven-
tilation to prevent condensation, and may promote corrosion and oxi-
dation.
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MAINTENANCE
Removal from Storage
1. Check the battery electrolyte level and charge the battery if neces-
sary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 33.
NOTE: Tightness of the bolts, nuts and other fasteners should be checked by
an authorized Polaris dealer.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 52.
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness or death. Never run an engine in an enclosed area.
Transporting the RANGER
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Remove the key to prevent loss during transporting.
3. Place the transmission in gear.
4. Engage the park brake.
5. Secure the fuel cap, oil cap and seat.
6. Always tie the frame of the RANGER to the transporting unit
securely with suitable straps or rope. Do not attach tie straps to the
front A-arm bolt pockets.
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SPECIFICATIONS
RANGER 4X4 500 EFI
Gross Vehicle Weight
Dry Weight
2700 lbs. (1226 kg)
1185 lbs. (537 kg)
113 in. (282 cm)
60 in. (152.4 cm)
58 in. (147.3 cm)
75 in. (190.5 cm)
76 in. (193 cm)
Overall Length
Overall Width (box)
Overall Width (tires)
Overall Height
Wheelbase
Cargo Box (L x W x H)
Ground Clearance
Min. Turning Radius
Fuel Capacity
58 x 42 x 10 in. (147 x 106.7 x 25.4 cm)
11.5 in. (29 cm)
132 in. (335.3 cm)
9 gal. (34 l)
Engine Oil Capacity
Coolant Capacity
Towing Capacity
Max. Cargo Box Load
Engine
2 qts. (2.1 l)
2.25 qts. (2.4 l)
1500 lbs. (681 kg)
1000 lbs. (454 kg)
4 valve 4 stroke single cylinder with
counter balance
Displacement
499 cc
Bore x Stroke
92 x 75
Alternator Output
Compression Ratio
Starting System
Fuel System
250 W
10.2:1
Electric
Electronic Fuel Injection
CDI
Ignition System
Ignition Timing
Spark Plug
30° @5000 RPM
NGK BKR5E
Front Suspension
Rear Suspension
MacPherson strut w/8.25 in. (21 cm) of travel
Independent w/9 in. (23 cm) of travel
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SPECIFICATIONS
RANGER 4X4 500 EFI
Lubrication System
Engine Oil
Dry Sump
0W/40
Driving System Type
Shift Type
PVT
Single Lever (console)
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front:
Drive Ratio - Final
Tire Size - Front
Tire Size - Rear
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Brake, Park
8.71:1
5.9:1
3.83:1
3.83:1
3.70:1
25 x 10 - 12
25 x 11 - 12
8-12 psi
8-12 psi
Foot Activated, 4 wheel hydraulic disc
Foot activated, mechanical
2 dual beam, 35W, quartz/halogen
2 single beam, 5W
2 single beam, 5W
1.0 W
Hood Headlight
Taillights
Brake Light
Indicator Light
NOTE: See your Polaris dealer for clutching specifications.
101
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POLARIS PRODUCTS
Part Number
Description
Engine Lubricant
2870791
2871281
2871844
Fogging Oil (12 oz. Aerosol)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)
Gearcase / Transmission Lubricants
Premium AGL Synthetic Gearcase Lubricant (qt.)
Premium AGL Synthetic Gearcase Lube (gal.)
Premium ATV Angle Drive Fluid (8 oz.)
Premium ATV Angle Drive Fluid (2.5 gal.)
Pump for Gallon Jug
2873602
2873603
2871653
2872276
2870465
2871654
2872277
Premium Demand Drive Hub Fluid (8 oz.)
Premium Demand Drive Hub Fluid (2.5 gal.)
Coolant
2871323
2871534
60/40 Coolant (gal.)
60/40 Coolant (qt.)
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season (3 oz.)
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Starter Drive Grease (2 oz.)
2871312
2871322
2871423
2871460
2871515
2871551
2871329
2872073
2872348
Premium U-Joint Lube (3 oz.)
Premium U-Joint Lube (14 oz.)
Dielectric Grease (NyogelTM
)
Chain Lube, Aerosol (6.25 oz.)
Chain Lube, Aerosol (16 oz.)
Additives / Miscellaneous
Brake and Clutch Cleaner
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT 4 Brake Fluid
DOT 3 Brake Fluid
Engine Degreaser (12 oz.)
LoctiteTM 565 Thread Sealant
Polaris Battery TenderTM Charger
2872889
2871326
2870652
2872189
2870990
2872893
2871956
2871076
102
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TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause
Solution
Driving onto a pickup or Use low range during loading.
tall trailer in high range
Starting out going up a
steep incline
Use low range. See warnings on page 38.
Driving at low RPM or
Drive at a higher speed or use low range more frequently.
ground speed (3-7 MPH) See page 72.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage- Use the throttle quickly and effectively.
ment
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing
Use low range only.
Stuck in mud or snow
Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water Dry out the PVT. See page 73. Inspect clutch seals for
or snow ingestion into the damage if repeated leaking occurs.
PVT system
Clutch malfunction
See your Polaris dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt
Improper break-in
Install the recommended belt.
Always break in a new belt and/or clutch. See pages 32
and 72.
103
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TROUBLESHOOTING
Engine Doesn't Turn Over
Possible Cause
Solution
Low battery voltage
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Loose battery connections
Loose solenoid connections
Loose electronic control box connections Inspect, clean, reinstall connectors
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Solution
Refuel
Clogged fuel filter
Inspect and clean or replace
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plugs
No spark to spark plug
Water or fuel in crankcase
Low battery voltage
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs and replace if necessary
Immediately see your Polaris dealer
Recharge the battery to 12.8 VDC
See your dealer
Mechanical failure
Engine Backfires
Possible Cause
Solution
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
Mechanical failure
See your dealer
Loose ignition connections
Water present in fuel
Check all connections and tighten
Replace with fresh recommended fuel
104
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TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Solution
Poor quality or low octane fuel
Incorrect ignition timing
Replace with recommended fuel
See your dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Solution
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Inspect, clean and/or replace spark plugs
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Low battery voltage
Recharge battery to 12.8 VDC
Inspect and replace
Kinked or plugged fuel tank vent line
Incorrect fuel
Replace with recommended fuel
Inspect and clean or replace
See your dealer
Clogged air filter
Other mechanical failure
Possible Lean Fuel Cause
Solution
Low or contaminated fuel
Low octane fuel
Add or change fuel, clean the fuel system
Replace with recommended fuel
Replace filter
Clogged fuel filter
Possible Rich Fuel Cause
Solution
Fuel is very high octane
Replace with lower octane fuel
105
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TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Solution
Out of fuel
Refuel
Inspect and replace
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Replace with new fuel
Inspect, clean and/or replace spark plug
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
Incorrect fuel
Clogged air filter
Other mechanical failure
Overheated engine
Clean radiator screen and core, clean
engine exterior, see your dealer
106
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WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-
ITED WARRANTY on all components of the Polaris RANGER against defects in mate-
rial or workmanship. Polaris also gives a one year limited warranty on the final drive
chain for failure due to defects. This warranty covers the parts and labor charges for
repair or replacement of defective parts which are covered by this warranty. This war-
ranty begins on the date of purchase. This warranty is transferable to another consumer
during the warranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any vehicle that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the vehicle. The exclusive remedy for breach of this warranty
shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or
components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE
THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP-
TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR
ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
Some states do not permit the exclusion or limitation of incidental or consequential
damages or implied warranties, so the above limitations or exclusions may not apply to
you if inconsistent with controlling state law.
107
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WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-
tations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer.
When requesting warranty service you must present your copy of the Warranty Registra-
tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE
DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original
selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty
service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Lubricants
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
SPARK ARRESTOR
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-
ments of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and
when maintenance and installation are in accordance with Polaris recommendations.
108
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WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer's authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to per-
form the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100
109
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WARRANTY
U.S.A. EPA Emissions Limited Warranty
This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited
warranty is in addition to the Polaris standard limited warranty for this vehicle.
Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the
time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in
materials and workmanship that may keep it from meeting these requirements.
The emissions warranty period for this vehicle begins on the date the vehicle is deliv-
ered to the original retail purchaser and ends 30 months (2.5 years) after that date, or
after 5000 km (3100 miles), whichever comes first.
This emission-related warranty covers components whose failure would increase an
engine's emissions, including electronic controls, fuel injection, exhaust-gas recircula-
tion, aftertreatment, or any other system utilized in this vehicle to control emissions.
Replacing or repairing other components not covered by this emissions warranty or the
standard warranty is the responsibility of the owner; including the parts, labor and other
costs associated with recommended maintenance.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of Polaris, repair or replacement of any defective materials, components or prod-
ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-
TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on
how long an implied warranty lasts, so the above limitation may not apply if it is incon-
sistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workman-
ship. This limited warranty does not cover damage due to accidents, abuse or improper
handling, maintenance or use. This limited warranty also does not cover any engine that
has been structurally altered, or any engine that has been used in racing competition.
This limited warranty also does not cover physical damage, corrosion or defects caused
by fire, explosions or other similar causes beyond the control of Polaris.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the Polaris Warranty Department at 1-763-417-8650.
110
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WARRANTY
California Emission Control Warranty Statement
The Air Index of this Engine is 3
0
2
4
6
8
10
Most Clean
Least Clean
Note: The lower the Air Index, the less pollution.
This engine is certified to be emission compliant
for 1000 hours of use.
Your Warranty Rights and Obligations
The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55,
Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con-
trol system warranty on your 2005 and later Large Spark Ignition Engine (herein "LSI
engine"). "The California Air Resources Board has designated this engine for this vehi-
cle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six
(6) or four (4)-wheel drive and/or a round steering wheel." In California, this LSI engine
must be designed, built and equipped to meet the state's stringent anti-smog standards.
Polaris must warrant the emission control system on your LSI engine for the period of
time described below, provided there has been no abuse, neglect or improper mainte-
nance of your LSI engine.
Your emission control system includes parts such as the carburetor and the ignition sys-
tem. Also included may be hoses, connectors and other emission-related assemblies.
Where a warrantable condition exists, POLARIS will repair your LSI engine at no cost
to you, including diagnosis, parts and labor.
Manufacturer's Warranty Coverage:
The 2005 and later LSI engines are warranted for two (2) years. If any emission related
part on your LSI engine is defective, the part will be repaired or replaced by POLARIS.
111
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WARRANTY
California Emission Control Warranty Statement
Owner's Warranty Responsibilities:
• As the LSI engine owner, you are responsible for the performance of the required
maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's
Manual"). POLARIS recommends that you retain all receipts covering maintenance
on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts
or for your failure to ensure the performance of all scheduled maintenance.
• As the LSI engine owner, you should, however, be aware that POLARIS may deny
you warranty coverage if your LSI engine or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
• You are responsible for presenting your LSI engine to a dealer authorized by
POLARIS as soon as a problem exists. The warranty repairs should be completed in a
reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the Polaris Warranty Department at 1-763-417-8650.
Limited Warranty California Only
POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1)
has been designed, built, and equipped at the time of manufacture so as to conform with
the applicable regulations of the California Air Resources Board and, (2) is free from
defects in materials and workmanship which may cause it to fail to conform with those
regulations as applicable according to the terms and conditions stated below.
Warranty Period
This warranty period begins on the date, which the LSI engine is delivered, to the origi-
nal retail purchaser and ends two years after that date. During this two year period
POLARIS warrants to the original retail purchaser and each subsequent purchaser that
the LSI engine is free from defect in material and workmanship that can cause the fail-
ure of a warranted emission-related part.
What is Covered Under This Warranty
Repair and/or replacement of any warranted emission-related part will be performed at
no charge provided the work is performed at an authorized dealer. There will also be no
charge for any diagnostic labor performed at an authorized dealer, which leads to the
determination that a warranted emission-related part is defective.
Any warranted part which is not scheduled for replacement as required maintenance, or
which is scheduled only for regular inspection to the effect of "repair or replace as nec-
essary" shall be warranted for the warranty period. Any warranted part which is sched-
uled for replacement as required maintenance shall be warranted for the period of time
up to the first scheduled replacement of that part. This warranty shall apply only towards
the repair, replacement, and/or adjustment of the component parts listed below.
112
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WARRANTY
California Emission Control Warranty Statement
Emission-Related Parts Covered Under This Warranty
(1) Fuel Metering System
(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)
(ii) Air/fuel ratio feedback and control system, if applicable
(iii) Cold start enrichment system, if applicable
(iv) Regulator assy (gaseous fuel, if applicable)
(2) Air Induction System
(i) Intake manifold, if applicable
(ii) Air filter
(3) Ignition System
(i) Spark plugs
(ii) Magneto or electronic ignition system
(iii) Spark advance/retard system, if applicable
(4) Exhaust manifold, if applicable
(5) Miscellaneous Items Used in Above Systems
(i) Electronic controls, if applicable
(ii) Hoses, belts, connectors, and assemblies
(iii) Filter lock assy (gaseous fuel, if applicable)
If an authorized dealer determines that other LSI engine components have been dam-
aged due to the failure of a warranted emission-related part during the warranty period,
POLARIS will repair and/or replace the necessary components.
113
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WARRANTY
California Emission Control Warranty Statement
What is Not Covered Under This Warranty
This warranty does not cover any emission-related part which malfunctions, fails or is
damaged due to alterations and/or modifications such as changing, adding or removing
parts.
When the LSI engine is being serviced under warranty, POLARIS and any of its autho-
rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to
goods, or loss of time or inconvenience. This limited warranty also does not apply to any
emission-related part which malfunctions, fails, or is damaged due to failure to follow
the maintenance and operating instructions specified in the 2005 and later Owner's Man-
ual including:
(a) Improper or inadequate maintenance of any warranted emission-related part
(b) Improper installation, adjustment, or repair of the LSI engine or any warranted
emission-related part unless performed by an authorized dealer
(c) Failure to use recommended fuel as specified in the 2005 and later Owner's Manual
(d) Repairs and diagnosis performed outside of an authorized dealer
(e) Use of parts which are not authorized by POLARIS
Maintenance Schedule
The LSI engine owner is responsible for having all scheduled inspection and mainte-
nance services performed at the intervals specified in the 2005 and later Owner's Manual
and to retain records of these services as having been performed. These records should
be transferred to each subsequent owner of the LSI engine. POLARIS cannot deny a
claim solely because there are no records of scheduled maintenance, however, a war-
ranty claim may be denied if the failure to perform the scheduled maintenance and
inspection resulted in the failure of a warranted emission-related part. As a minimum,
the LSI engine owner is responsible for the scheduled inspection and maintenance
described below which are based on the procedures described in the Owner's Manual.
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WARRANTY
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
X Air filter, pre-filter
-
-
Daily
Daily
Weekly
Monthly
6 M
-
-
-
-
-
-
-
-
Inspect; clean often
E
X Air box sediment
E tube
Drain deposits when visible
Inspect; replace as needed
Inspect; replace if necessary
X Air filter,
E main element
-
X Engine breather
E filter (if equipped)
25H
50H
50H
100 H
100 H
Q
E
Throttle Cable/
ETC Switch
Inspect; adjust; lubricate;
replace if necessary
E Throttle body air
6 M
Inspect ducts for proper seal-
ing/air leaks
intake ducts/flange
Q
E
Valve clearance
12M
Inspect; adjust
Q
E
Fuel system
12 M
Check for leaks at tank cap,
lines, fuel valve, filter, pump,
throttle body; replace lines
every two years
Q
E
Spark plug
100 H
12 M
-
Inspect; replace as needed
Repair and Replacement of Emission-Related Parts
It is recommended that only LSI engine replacement parts, which have
been authorized and approved by POLARIS, should be used in the per-
formance of any warranty maintenance or repairs of emission-related
parts. These replacement parts will be provided at no charge if the part is
still under warranty.
How to File a Warranty Claim/Where to Get Warranty Service
All repairs qualifying under this Limited Warranty must be performed
by a dealer who sold you the LSI engine or a dealer authorized by
POLARIS. In the event that any emission-related part is found to be
defective during the warranty period, you must notify the Polaris War-
ranty Department at 1-763-417-8650 and you will be advised of the
appropriate dealer where the warranty repair is to be performed.
115
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MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
116
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MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
117
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INDEX
A
C
Adding Coolant . . . . . . . . . . . . . . . . 69
Adjustment
Changing Oil
Engine . . . . . . . . . . . . . . . . . . . . 60
Front Gearcase. . . . . . . . . . . . . . 65
Rear Gearcase . . . . . . . . . . . . . . 66
Transmission/Main Gearcase . . 64
Chart, Gearcase Specifications . . . . . 63
Chart, Periodic Maintenance . . . . 52-56
Checking Oil Level
Engine . . . . . . . . . . . . . . . . . . . . 59
Front Gearcase. . . . . . . . . . . . . . 65
Rear Gearcase . . . . . . . . . . . . . 66
Transmission/Main Gearcase . . 63
Chrome Wheel Care . . . . . . . . . . . . . 96
Cleaning and Storage. . . . . . . . . . 94-98
Cleaning the Air Filter. . . . . . . . . . . . 74
Cleaning the Exhaust System . . . . . . 76
Cleaning the Fuel Filter. . . . . . . . . . . 74
Cleaning the Spark Arrestor . . . . . . . 76
Component Locations . . . . . . . . . 22-25
Console . . . . . . . . . . . . . . . . . . . . . . . 28
Coolant
Bottle Level . . . . . . . . . . . . . . . . 70
Radiator Level . . . . . . . . . . . . . . 71
Adding or Changing . . . . . . . . . 69
Cooling Fan . . . . . . . . . . . . . . . . . . . . 70
Cooling System . . . . . . . . . . . . . . 70-71
Cooling System Operation. . . . . . . . . 69
Corrosion Removal, Chrome. . . . . . . 96
Cover for Storage. . . . . . . . . . . . . . . . 98
Crankcase Emission Control System. 51
Cylinder Head . . . . . . . . . . . . . . . . . . 78
Headlight Beam . . . . . . . . . . . . 86
Park Brake . . . . . . . . . . . . . . . . 80
Rear Spring . . . . . . . . . . . . . . . 81
Rear Suspension . . . . . . . . . . . 81
Throttle Freeplay . . . . . . . . . . . 78
Age Restrictions. . . . . . . . . . . . . . . . . 8
Air Filter . . . . . . . . . . . . . . . . . . . . . 74
Air Filter Cleaning. . . . . . . . . . . . . . 74
All Wheel Drive. . . . . . . . . . . . . . . . 50
All Wheel Drive Lock Switch . . . . . 31
Arrestor, Spark, Warning. . . . . . . . . 76
Auxiliary Outlet. . . . . . . . . . . . . . . . 25
AWD . . . . . . . . . . . . . . . . . . . . . . . . 50
AWD/Differential Lock Switch. . . . 31
Axle Nut Torque . . . . . . . . . . . . . . . 83
B
Battery
Charging (Conventional) . . . . . 92
Charging (Sealed Battery) . . 92-93
Conventional . . . . . . . . . . . . . . 88
Fluid Replenishment . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . 90
Removal. . . . . . . . . . . . . . . . . . 89
Storage. . . . . . . . . . . . . . . . . . . 91
Beam Adjustment, Headlight. . . . . . 86
Before Riding. . . . . . . . . . . . . . . . . . 33
Belt Burning. . . . . . . . . . . . . . . . . . 103
Belt Life. . . . . . . . . . . . . . . . . . . . . . 47
Belt Wear. . . . . . . . . . . . . . . . . . . . 103
Belts, Seat . . . . . . . . . . . . . . . . . 27, 82
Brake
Fluid. . . . . . . . . . . . . . . . . . . . . 79
Inspection. . . . . . . . . . . . . . . . . 80
Lights. . . . . . . . . . . . . . . . . . . . 87
Park . . . . . . . . . . . . . . . . . . . . . 30
Park Brake Adjustment . . . . . . 80
Pedal . . . . . . . . . . . . . . . . . . . . 30
Braking . . . . . . . . . . . . . . . . . . . . . . 35
Break-In Period . . . . . . . . . . . . . . . . 32
Breather Filter . . . . . . . . . . . . . . . . . 75
Burning Belts. . . . . . . . . . . . . . . . . 103
D
Differential Lock Switch . . . . . . . . . . 31
Differential Operation . . . . . . . . . . . . 49
Disengaging AWD . . . . . . . . . . . . . . 50
Drive Belt Wear. . . . . . . . . . . . . . . . 103
Driving Downhill. . . . . . . . . . . . . . . . 39
Driving in Reverse. . . . . . . . . . . . . . . 42
Driving on a Sidehill . . . . . . . . . . . . . 39
Driving on Slippery Surfaces . . . . . . 37
Driving Over Obstacles . . . . . . . . . . . 41
Driving Procedure . . . . . . . . . . . . . . . 36
Driving Safely . . . . . . . . . . . . . . . 36-48
Driving Through Water . . . . . . . . . . . 40
Driving Uphill . . . . . . . . . . . . . . . . . . 38
Driving, After Driving in Water . . . . 73
Drying the Transmission . . . . . . . . . . 73
Dumping the Cargo Box . . . . . . . . . . 46
C
Capacity, Weight . . . . . . . . . . . . . . . 45
Cargo . . . . . . . . . . . . . . . . . . . . . . 44-45
Cargo Box, Dumping. . . . . . . . . . . . 46
Changing Coolant . . . . . . . . . . . . . . 69
Changing Gears . . . . . . . . . . . . . . . . 29
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INDEX
E
G
Electromagnetic Interference . . . . . . 51
Emission Control, Crankcase . . . . . . 51
Emission Control, Exhaust . . . . . . . . 51
Emission Control, Noise. . . . . . . . . . 51
Emissions Limited Warranty . . . . . 110
Engine Fogging. . . . . . . . . . . . . . . . . 98
Engine Idle Speed . . . . . . . . . . . . . . . 78
Engine Oil. . . . . . . . . . . . . . . . . . 58-62
Engine Starting . . . . . . . . . . . . . . . . . 34
Engine Stopping . . . . . . . . . . . . . . . . 35
Equipment Modifications . . . . . . . . . 13
Exhaust Cleaning . . . . . . . . . . . . . . . 76
Exhaust Emission Control System . . 51
Exhaust System Warning . . . . . . . . . 76
Gearcase Specification Chart . . . . . . 63
Gearcases . . . . . . . . . . . . . . . . . . 63-66
Gears, Shifting . . . . . . . . . . . . . . . . . 29
H
Hauling Cargo. . . . . . . . . . . . . . . 44-45
Headlight Beam Adjustment. . . . . . . 86
Headlight Lamp Replacement . . . . . 85
Hitch Weight. . . . . . . . . . . . . . . . . . . 47
I
Idle Speed . . . . . . . . . . . . . . . . . . . . . 78
Ignition Switch . . . . . . . . . . . . . . . . . 31
Indicator Light Replacement . . . . . . 87
Indicator Lights. . . . . . . . . . . . . . . . . 25
Inspection
F
Fan, Cooling . . . . . . . . . . . . . . . . . . . 70
Fastener Torque,
Axle Nuts . . . . . . . . . . . . . . . . . 83
Brakes . . . . . . . . . . . . . . . . . . . . 80
Park Brake . . . . . . . . . . . . . . . . 80
Pre-Ride . . . . . . . . . . . . . . . . . . 33
Seat Belts . . . . . . . . . . . . . . . . . 82
Steering Wheel . . . . . . . . . . . . . 81
Throttle Freeplay . . . . . . . . . . . 77
Wheel Nuts . . . . . . . . . . . . . . . . 83
Installation, Battery. . . . . . . . . . . . . . 90
Installation, Wheels . . . . . . . . . . . . . 84
Interference, Electromagnetic. . . . . . 51
Cylinder Head/Base . . . . . . . . . 78
Filling the Battery . . . . . . . . . . . . . . . 91
Filter Care During Storage . . . . . . . . 97
Filter Change. . . . . . . . . . . . . . . . . . . 60
Filter Cleaning, Air. . . . . . . . . . . . . . 74
Filter Cleaning, Fuel . . . . . . . . . . . . . 74
Filter Systems . . . . . . . . . . . . . . . 74-75
Filter
Air . . . . . . . . . . . . . . . . . . . . . . . 74
Breather. . . . . . . . . . . . . . . . . . . 75
Fuel . . . . . . . . . . . . . . . . . . . . . . 74
Fluid Levels During Storage. . . . . . . 97
Fluid, Battery . . . . . . . . . . . . . . . . . . 91
Fluid, Brake . . . . . . . . . . . . . . . . . . . 79
Fogging the Engine. . . . . . . . . . . . . . 98
Fouled Plugs . . . . . . . . . . . . . . . . . . . 68
Freeplay, Throttle . . . . . . . . . . . . 77-78
Freeplay, Steering Wheel . . . . . . . . . 81
Front Gearcase
Lubrication . . . . . . . . . . . . . . . . 65
Oil Change . . . . . . . . . . . . . . . . 65
Oil Check . . . . . . . . . . . . . . . . . 65
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 26
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 74
Fuel Gauge . . . . . . . . . . . . . . . . . . . . 26
Fuel Safety . . . . . . . . . . . . . . . . . . . . 21
Fuel Stabilizer. . . . . . . . . . . . . . . . . . 97
K
Key, Periodic Maintenance Chart. . . 53
L
Lamp Replacement, Headlight . . . . . 85
Lamp Replacement, Indicator Lights 87
Life of Belt . . . . . . . . . . . . . . . . . . . . 47
Light Switch . . . . . . . . . . . . . . . . . . . 31
Lights . . . . . . . . . . . . . . . . . . . . . 85-87
Lights, Brake. . . . . . . . . . . . . . . . . . . 87
Lights, Indicator . . . . . . . . . . . . . . . . 25
Load Capacity. . . . . . . . . . . . . . . . . . 45
Loads, Towing . . . . . . . . . . . . . . . . . 47
Lubricant Part Numbers . . . . . . . . . 102
Lubrication
For Storage . . . . . . . . . . . . . . . . 97
Recommendations. . . . . . . . . . . 57
Front Gearcase . . . . . . . . . . . . . 65
Gearcase . . . . . . . . . . . . . . . . . . 63
Main Gearcase . . . . . . . . . . . . . 63
Rear Gearcase . . . . . . . . . . . . . . 66
Transmission. . . . . . . . . . . . . . . 63
G
Gap, Spark Plug . . . . . . . . . . . . . . . . 67
Gear Selector. . . . . . . . . . . . . . . . . . . 29
Gearcase Lubrication . . . . . . . . . . . . 63
119
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INDEX
M
P
Main Gearcase
Polaris Products. . . . . . . . . . . . . . . . 102
Polishing the Vehicle. . . . . . . . . . . . . 95
Premium 4 Synthetic Oil . . . . . . . . . . 58
Pre-Ride Inspection . . . . . . . . . . . . . . 33
Pressure, Tire. . . . . . . . . . . . . . . . . . . . 5
Public Lands . . . . . . . . . . . . . . . . . . . 51
PVT Drying . . . . . . . . . . . . . . . . . . . . 73
PVT System. . . . . . . . . . . . . . . . . . . . 73
PVT System Operation . . . . . . . . . . . 72
Lubrication. . . . . . . . . . . . . . . . 63
Oil Change. . . . . . . . . . . . . . . . 64
Oil Check. . . . . . . . . . . . . . . . . 63
Maintenance Log . . . . . . . . . . . 116-117
Maintenance, Periodic . . . . . . . . . 52-56
Modifications. . . . . . . . . . . . . . . . . . 13
N
Noise Emission Control System . . . 51
R
O
Radiator . . . . . . . . . . . . . . . . . . . . . . . 70
Radiator Coolant Level . . . . . . . . . . . 71
Rear Gearcase
Obstacles . . . . . . . . . . . . . . . . . . . . . 41
Oil and Filter Care During Storage . 97
Oil and Filter Change. . . . . . . . . . 61-62
Oil Change
Lubrication. . . . . . . . . . . . . . . . . 66
Oil Change. . . . . . . . . . . . . . . . . 66
Oil Check. . . . . . . . . . . . . . . . . . 66
Rear Spring Adjustment . . . . . . . . . . 81
Rear Suspension Adjustment. . . . . . . 81
Release, Park Brake. . . . . . . . . . . . . . 30
Removal, Battery. . . . . . . . . . . . . . . . 89
Removal, Seat . . . . . . . . . . . . . . . . . . 26
Removal, Wheels. . . . . . . . . . . . . . . . 84
Removing the Vehicle from Storage . 99
Replacement, Headlight Lamp . . . . . 85
Reverse . . . . . . . . . . . . . . . . . . . . . . . 42
RPM, Idle, Throttle Body . . . . . . . . . 78
Engine . . . . . . . . . . . . . . . . . . . 60
Front Gearcase. . . . . . . . . . . . . 65
Main Gearcase . . . . . . . . . . . . . 64
Rear Gearcase . . . . . . . . . . . . . 66
Transmission . . . . . . . . . . . . . . 64
Oil Check
Engine . . . . . . . . . . . . . . . . . . . 59
Front Gearcase. . . . . . . . . . . . . 65
Main Gearcase . . . . . . . . . . . . . 63
Rear Gearcase . . . . . . . . . . . . . 66
Transmission . . . . . . . . . . . . . . 63
Oil Pump Priming . . . . . . . . . . . . . . 62
Oil, Engine. . . . . . . . . . . . . . . . . . 58-62
Oil, Synthetic. . . . . . . . . . . . . . . . . . 58
Operation on Public Lands . . . . . . . 51
Operation, Cooling System . . . . . . . 69
Operation, Transmission . . . . . . . . . 72
Operator Safety . . . . . . . . . . . . . . . 8-20
Outlet, Auxiliary . . . . . . . . . . . . . . . 25
S
Safety Decals. . . . . . . . . . . . . . . . . . 5-7
Safety Symbols . . . . . . . . . . . . . . . . . . 9
Seat Belt Inspection. . . . . . . . . . . . . . 82
Seat Belts. . . . . . . . . . . . . . . . . . . 27, 82
Seat Removal. . . . . . . . . . . . . . . . . . . 26
Selector, Gear . . . . . . . . . . . . . . . . . . 29
Severe Use Definition . . . . . . . . . . . . 52
Shifter . . . . . . . . . . . . . . . . . . . . . . . . 29
Shifting Gears . . . . . . . . . . . . . . . . . . 29
Signal Words . . . . . . . . . . . . . . . . . . . . 9
Spark Arrestor Warning. . . . . . . . . . . 76
Spark Arrestor, Cleaning. . . . . . . . . . 76
Spark Plug
P
Park Brake
Adjustment. . . . . . . . . . . . . . . . 80
Inspection. . . . . . . . . . . . . . . . . 80
Pedal . . . . . . . . . . . . . . . . . . . . 30
Release. . . . . . . . . . . . . . . . . . . 30
Parking on an Incline. . . . . . . . . . . . 43
Parking the Vehicle . . . . . . . . . . . . . 48
Periodic Maintenance Chart . . . . 52-56
Plug
Condition . . . . . . . . . . . . . . . . . . 68
Gap. . . . . . . . . . . . . . . . . . . . . . . 67
Removal. . . . . . . . . . . . . . . . . . . 68
Torque . . . . . . . . . . . . . . . . . . . . 67
Fouled . . . . . . . . . . . . . . . . . . . . 68
Specifications. . . . . . . . . . . . . . 100, 101
Specifications, Gearcase . . . . . . . . . . 63
Speed, Idle . . . . . . . . . . . . . . . . . . . . . 78
Condition . . . . . . . . . . . . . . . . . 68
Gap. . . . . . . . . . . . . . . . . . . . . . 67
Torque . . . . . . . . . . . . . . . . . . . 67
Fouled . . . . . . . . . . . . . . . . . . . 68
Spark . . . . . . . . . . . . . . . . . . . . 67
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INDEX
S
T
Speed, Towing . . . . . . . . . . . . . . . . . 47
Spring, Rear, Adjustment . . . . . . . . . 81
Stabilizing the Fuel . . . . . . . . . . . . . . 97
Starting the Engine . . . . . . . . . . . . . . 34
Steering Wheel Inspection . . . . . . . . 81
Stopping the Engine . . . . . . . . . . . . . 35
Storage . . . . . . . . . . . . . . . . . . . . 94-98
Storage and Inspection . . . . . . . . . . . 97
Storage and Lubrication . . . . . . . . . . 97
Storage
Torque, Axle Nuts . . . . . . . . . . . . . . 83
Torque, Spark Plug . . . . . . . . . . . . . . 67
Torque, Wheel Nut . . . . . . . . . . . . . . 83
Towing Loads . . . . . . . . . . . . . . . . . . 47
Towing Speed . . . . . . . . . . . . . . . . . . 47
Trailer Hitch Bracket . . . . . . . . . . . . 25
Transmission
Lubrication . . . . . . . . . . . . . . . . 63
Oil Change . . . . . . . . . . . . . . . . 64
Oil Check . . . . . . . . . . . . . . . . . 63
Operation . . . . . . . . . . . . . . . . . 72
Transmission System . . . . . . . . . . . . 73
Transmission, Drying . . . . . . . . . . . . 73
Transporting the Vehicle . . . . . . . . . 99
Tread Depth . . . . . . . . . . . . . . . . . . . 83
Area. . . . . . . . . . . . . . . . . . . . . . 98
Battery. . . . . . . . . . . . . . . . . . . . 91
Covers . . . . . . . . . . . . . . . . . . . . 98
Fluid Levels . . . . . . . . . . . . . . . 97
Oil and Filter. . . . . . . . . . . . . . . 97
Removal . . . . . . . . . . . . . . . . . . 99
Suspension Adjustment, Rear. . . . . . 81
Switches
AWD/Differential Lock . . . . . . 31
Ignition . . . . . . . . . . . . . . . . . . . 31
Light . . . . . . . . . . . . . . . . . . . . . 31
Synthetic Oil . . . . . . . . . . . . . . . . . . . 58
V
Vehicle Break In. . . . . . . . . . . . . . . . 32
Vehicle Identification Numbers . . . . . 4
Vehicle Immersion . . . . . . . . . . . . . . 73
Vehicle Transport . . . . . . . . . . . . . . . 99
W
T
Warning Symbols . . . . . . . . . . . . . . . . 9
Washing the Vehicle. . . . . . . . . . 94-95
Water, Immersion of Vehicle . . . . . . 73
Wear, Drive Belt. . . . . . . . . . . . . . . 103
Weight Capacity . . . . . . . . . . . . . . . . 45
Weight, Hitch . . . . . . . . . . . . . . . . . . 47
Wheel Installation. . . . . . . . . . . . . . . 84
Wheel Nut Torque . . . . . . . . . . . . . . 83
Wheel Removal . . . . . . . . . . . . . . . . 84
Throttle Freeplay
Adjustment . . . . . . . . . . . . . . . . 78
Inspection . . . . . . . . . . . . . . . . . 77
Throttle Pedal . . . . . . . . . . . . . . . . . . 30
Throttle System. . . . . . . . . . . . . . 77-78
Tire Pressure . . . . . . . . . . . . . . . . . . . . 5
Tire Tread Depth. . . . . . . . . . . . . . . . 83
Tires . . . . . . . . . . . . . . . . . . . . . . 83-84
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