Polaris Offroad Vehicle 2005 99 Ranger User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARNING  
The engine exhaust from this  
product contains chemicals known  
to cause cancer, birth defects or  
other reproductive harm.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FOREWORD  
Congratulations and thank you from Polaris Industries Inc. for purchasing one of  
our products. Built with American engineering and manufacturing know-how, it is  
designed to provide superior comfort, utility, enjoyment and safety.  
This manual is furnished to ensure that the operator is aware of safe operating pro-  
cedures. It also includes information about the general care and maintenance of  
your vehicle.  
Carefully read the following pages. If you have any questions regarding this ve-  
hicle contact a Polaris dealer for assistance. Remember, Polaris dealers have the  
knowledge and facilities to provide you with the best service possible.  
PROTECT YOUR SPORT  
Know all local, state/province off-road vehicle laws;  
Respect your vehicle;  
Respect the environment; and  
You will gain the respect of others.  
We also advise you to strictly follow the recommended maintenance program as  
outlined. This preventive maintenance program is designed to ensure that all criti-  
cal components on this vehicle are thoroughly inspected at various intervals.  
All information in this manual is based upon the latest product data and specifica-  
tions available at the time of printing. Polaris Industries Inc. reserves the right to  
make product changes and improvements which may affect illustrations or ex-  
planations.  
No part of this manual shall be reproduced or used without the written permission  
of Polaris Industries Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.  
This vehicle handles differently from other vehicles including motor-  
cycles and cars. A collision or rollover can occur quickly, even during rou-  
tine maneuvers such as turning and driving on hills or over obstacles, if you  
fail to take proper precautions.  
SEVERE INJURY OR DEATH can result if you do not follow these instructions:  
S
R
e
a
d
t
h
i
s
m
a
n
u
a
l
a
n
d
a
l
l
l
a
b
e
l
s
c
a
r
e
f
u
l
l
y
a
n
d
f
o
l
l
o
w
t
h
e
o
p
e
r
a
t
i
n
g
p
r
o
c
e
d
u
r
e
s
described.  
S
N
e
v
e
r
a
l
l
o
w
a
n
y
o
n
e
w
i
t
h
o
u
t
a
v
a
l
i
d
d
r
i
v
e
r
’
s
l
i
c
e
n
s
e
t
o
o
p
e
r
a
t
e
t
h
i
s
v
e
h
i
c
l
e
.
S 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 seatbelts at all times.  
S
N
e
v
e
r
p
e
r
m
i
t
a
g
u
e
s
t
t
o
o
p
e
r
a
t
e
t
h
i
s
v
e
h
i
c
l
e
u
n
l
e
s
s
t
h
e
g
u
e
s
t
h
a
s
r
e
a
d
t
h
i
s
manual and all product labels.  
S
T
o
r
e
d
u
c
e
t
i
p
o
v
e
r
r
i
s
k
,
b
e
e
s
p
e
c
i
a
l
l
y
c
a
r
e
f
u
l
w
h
e
n
e
n
c
o
u
n
t
e
r
i
n
g
o
b
s
t
a
c
l
e
s
a
n
d
slopes, when braking on hills or during turns.  
S
A
l
w
a
y
s
f
a
s
t
e
n
y
o
u
r
s
e
a
t
b
e
l
t
s
s
e
c
u
r
e
l
y
a
r
o
u
n
d
y
o
u
.
S
T
h
i
s
v
e
h
i
c
l
e
i
s
f
o
r
o
f
f
r
o
a
d
u
s
e
o
n
l
y
.
N
e
v
e
r
o
p
e
r
a
t
e
o
n
p
u
b
l
i
c
r
o
a
d
s
a
s
s
e
v
e
r
e
injury or death may occur. Always avoid paved surfaces.  
S
H
e
l
m
e
t
s
a
r
e
r
e
c
o
m
m
e
n
d
e
d
w
h
e
n
e
v
e
r
d
r
i
v
i
n
g
t
h
i
s
v
e
h
i
c
l
e
i
n
a
n
a
g
g
r
e
s
s
i
v
e
m
a
n
-
ner. Eye protection is recommended at all times.  
S
N
e
v
e
r
c
o
n
s
u
m
e
a
l
c
o
h
o
l
o
r
d
r
u
g
s
b
e
f
o
r
e
o
r
w
h
i
l
e
o
p
e
r
a
t
i
n
g
t
h
i
s
v
e
h
i
c
l
e
.
S
N
e
v
e
r
o
p
e
r
a
t
e
a
t
e
x
c
e
s
s
i
v
e
s
p
e
e
d
s
.
A
l
w
a
y
s
t
r
a
v
e
l
a
t
a
s
p
e
e
d
w
h
i
c
h
i
s
p
r
o
p
e
r
for the terrain, visibility and operating conditions, and your experience.  
S
N
e
v
e
r
a
t
t
e
m
p
t
w
h
e
e
l
i
e
s
,
j
u
m
p
s
o
r
o
t
h
e
r
s
t
u
n
t
s
.
S Always inspect your vehicle each time you use it to make sure it is in safe operat-  
ing condition. Always follow the inspection and maintenance procedures and  
schedules described in this manual.  
S
A
l
w
a
y
s
k
e
e
p
b
o
t
h
h
a
n
d
s
o
n
t
h
e
s
t
e
e
r
i
n
g
w
h
e
e
l
a
n
d
b
o
t
h
f
e
e
t
o
n
t
h
e
f
l
o
o
r
b
o
a
r
d
s
of the vehicle during operation.  
S
A
l
w
a
y
s
g
o
s
l
o
w
l
y
a
n
d
b
e
e
x
t
r
a
c
a
r
e
f
u
l
w
h
e
n
o
p
e
r
a
t
i
n
g
o
n
u
n
f
a
m
i
l
i
a
r
t
e
r
r
a
i
n
.
A
l
-
ways be alert to changing terrain conditions when operating this vehicle.  
S
N
e
v
e
r
o
p
e
r
a
t
e
o
n
e
x
c
e
s
s
i
v
e
l
y
r
o
u
g
h
,
s
l
i
p
p
e
r
y
o
r
l
o
o
s
e
t
e
r
r
a
i
n
.
S Always follow proper procedures for turning as described in this manual. Prac-  
tice turning at low speeds before attempting to turn at faster speeds. Do not turn  
at excessive speed.  
S
A
l
w
a
y
s
h
a
v
e
t
h
i
s
v
e
h
i
c
l
e
c
h
e
c
k
e
d
b
y
a
n
a
u
t
h
o
r
i
z
e
d
P
o
l
a
r
i
s
d
e
a
l
e
r
i
f
i
t
h
a
s
b
e
e
n
involved in an accident.  
S
N
e
v
e
r
o
p
e
r
a
t
e
t
h
i
s
v
e
h
i
c
l
e
o
n
h
i
l
l
s
t
o
o
s
t
e
e
p
f
o
r
t
h
e
v
e
h
i
c
l
e
o
r
f
o
r
y
o
u
r
a
b
i
l
i
t
i
e
s
.
Practice on smaller hills before attempting larger hills.  
S Always follow proper procedures for climbing hills as described in this manual.  
Check the terrain carefully before you start up any hill. Never climb hills with ex-  
cessively slippery or loose surfaces. Shift your weight forward. Never open the  
throttle suddenly or make sudden gear changes. Never go over the top of any  
hill at high speed.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
S Always follow proper procedures for going down hills and for braking on hills as  
described in this manual. Check the terrain carefully before you start down any  
hill. Never go down a hill at high speed. Avoid going down a hill at an angle  
which would cause the vehicle to lean sharply to one side. Go straight down the  
hill where possible.  
S Always follow proper procedures for crossing the side of a hill as described in  
this manual. Avoid hills with excessively slippery or loose surfaces. Never at-  
tempt to turn the vehicle around on any hill until you have mastered the turning  
technique described in this manual on level ground. Avoid crossing the side of  
a steep hill if possible.  
S Always use proper procedures if you stall or roll backwards when climbing a hill.  
To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll  
backwards, follow the special procedure for braking described in this manual.  
Dismount on the uphill side or to either side if pointed straight uphill. Turn the  
vehicle around and remount, following the procedure described in this manual.  
S Always check for obstacles before operating in a new area. Never attempt to  
operate over large obstacles, such as large rocks or fallen trees. Always follow  
proper procedures when operating over obstacles as described in this manual.  
S Always be careful of skidding or sliding. On slippery surfaces, such as ice, go  
slowly and be very cautious in order to reduce the chance of skidding or sliding  
out of control.  
S Never operate vehicle in fast flowing water or in water deeper than that specified  
in this manual. Remember that wet brakes may have reduced stopping ability.  
Test your brakes after leaving water. If necessary, apply them lightly several  
times to let friction dry out the pads.  
S Always be sure there are no obstacles or people behind you when you operate  
in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at  
sharp angles in reverse.  
S
A
l
w
a
y
s
u
s
e
t
h
e
s
i
z
e
a
n
d
t
y
p
e
t
i
r
e
s
s
p
e
c
i
f
i
e
d
i
n
t
h
i
s
m
a
n
u
a
l
.
A
l
w
a
y
s
m
a
i
n
t
a
i
n
proper tire pressure as described on page 83.  
S
N
e
v
e
r
m
o
d
i
f
y
t
h
i
s
v
e
h
i
c
l
e
t
h
r
o
u
g
h
i
m
p
r
o
p
e
r
i
n
s
t
a
l
l
a
t
i
o
n
o
r
u
s
e
o
f
a
c
c
e
s
s
o
r
i
e
s
.
S Never exceed the stated load capacity for this vehicle. Cargo should be proper-  
ly distributed and securely attached. Reduce speed and follow instructions in  
this manual for carrying cargo or pulling a trailer. Allow greater distance for brak-  
ing.  
S
A
l
w
a
y
s
w
e
a
r
t
h
e
s
e
a
t
b
e
l
t
s
w
h
e
n
e
v
e
r
t
h
e
v
e
h
i
c
l
e
i
s
o
p
e
r
a
t
e
d
.
T
h
i
s
w
i
l
l
r
e
d
u
c
e
the severity of injury in case of a sudden stop or collision.  
S
A
l
w
a
y
s
k
e
e
p
a
r
m
s
a
n
d
l
e
g
s
i
n
s
i
d
e
o
f
c
a
b
f
r
a
m
e
w
h
i
l
e
t
h
e
v
e
h
i
c
l
e
i
s
i
n
m
o
t
i
o
n
.
S Always apply the parking brake before getting out of the vehicle. The parking  
brake is located on the left side of the center console. Activate by pulling up on  
the lever. Release by pressing the button on the end of the handle and lowering  
the lever.  
S
A
l
w
a
y
s
a
c
t
i
v
a
t
e
t
h
e
f
o
o
t
p
e
d
a
l
b
r
a
k
e
b
e
f
o
r
e
r
e
l
e
a
s
i
n
g
t
h
e
p
a
r
k
b
r
a
k
e
.
S Always shut off the engine before refueling. Make sure the area is well venti-  
lated and free of any source of flame or sparks. Gasoline is very flammable.  
See page 24 for refueling instructions.  
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
indicates a potential hazard which  
could result in serious injury or death.  
WARNING  
Additional Important Information...  
Due to our concern for the safety of our customers and the general public, Polaris  
hereby strongly recommends and requests that consumers not have installed on  
a Polaris RANGER any equipment which is intended to increase the speed or pow-  
er of the vehicle; or make any other modifications to the vehicle for these purposes.  
Any modifications to the original equipment of the RANGER substantially increase  
the risk of bodily injury. Please be aware that these modifications may create a sub-  
stantial safety hazard.  
Polaris hereby informs you that the warranty on your RANGER is terminated if any  
such equipment has been added to the vehicle or any modifications have been  
made to the vehicle which increase its speed or power.  
We also advise you to strictly follow the recommended maintenance program out-  
lined in this manual. This preventive maintenance program is designed to ensure  
that all critical components on the vehicle are thoroughly inspected by your dealer  
at various mileage intervals.  
NOTE:  
The addition of certain accessories including (but not limited to) mowers, blades,  
tires, sprayers, or large racks may change the handling characteristics of the ve-  
hicle.  
Be certain any accessories added to this vehicle have been approved by Polaris.  
Familiarize yourself with their function and affect on the vehicle.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Polaris Preferred  
Registered Owners  
(PRO) Family  
Your Owners Program  
As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem-  
bership in the Polaris PRO Family-–the Preferred Registered Owners Family. It’s  
an owners program for Polaris owners like you, people who have chosen the finest  
recreational vehicle available, people who share an interest in Polaris and its prod-  
ucts.  
Once your new vehicle’s warranty is registered, you will receive a PRO Family  
membership packet that will include:  
A letter of welcome to the PRO Family  
A PRO Family card with your name and membership number  
A colorful sticker of the PRO logo  
A PRO merchandise brochure and order form.  
As a PRO Family member, you’re entitled to opportunities such as:  
A free subscription to PRO Spirit, the official magazine of the PRO Family  
The chance to buy insurance for you Polaris vehicle. The toll-free insurance  
telephone number is: 1-800-473-0111  
The chance to arrange travel through the Polaris Travel Center. The toll-free  
travel telephone number is: 1-800-267-1915  
The chance to apply to serve on PRO Consumer Councils that provide input  
into the Polaris vehicles of the future  
The chance to serve as a PRO Field Evaluator and provide feedback on your  
new vehicle  
The chance to purchase exclusive PRO Family merchandise  
And more!  
To order PRO merchandise, you’ll complete the order form you receive with your  
membership packet, take the form to your Polaris dealer and pay for the merchan-  
dise. The merchandise will be shipped directly to your home from the PRO mer-  
chandise fulfillment center.  
Watch for your PRO membership packet and the next issue of PRO Spirit maga-  
zine. This quarterly magazine will keep you informed about Polaris news and  
events, and special PRO merchandise, travel, and ride opportunities.  
Enjoy your new Polaris vehicle, and welcome to the family--The Polaris PRO Fami-  
ly.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTENTS  
UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
SAFETY WARNING AND OPERATION DECALS . . . . . . . . . . . . 2-7  
LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
DAILY PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19  
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . 20  
CONTROL AND PARTS FUNCTIONS . . . . . . . . . . . . . . . . . . . 21-39  
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43  
VEHICLE BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44  
CARRYING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
OPERATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-55  
NOISE EMISSION CONTROL SYSTEM REGULATION . . . . . . . 56  
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571–58  
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-88  
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89  
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-91  
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
UNDERSTANDING WARNINGS  
SAFETY ALERT  
The following precautionary signal words are used throughout this manual to con-  
vey the following messages:  
This is the safety alert symbol. When you see this symbol  
on your machine or in this manual, be alert to the potential  
for personal injury. Your safety is involved!  
Indicates a potential hazard  
which could result in serious  
injury or death.  
WARNING  
Indicates a potential hazard which  
may result in minor personal inju-  
ry or damage to the vehicle.  
CAUTION  
The word “NOTE:” in this manual will alert  
you to key information or instructions.  
NOTE  
WARNING  
HAZARD  
Failure to heed WARNINGS.  
WHAT CAN HAPPEN  
WARNINGS identify special instructions or procedures which, if not cor-  
rectly followed, could result in personal injury , or loss of life.  
HOW TO AVOID THE HAZARD  
Read all WARNINGS in this manual carefully and for your safety be  
sure to follow their instructions.  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
WARNING  
VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATH  
This cab frame is not designed or intended to provide rollover protection  
in the event of vehicle overturning. See Owner’s Manual.  
7077478  
l Riders can be thrown off.  
This can cause serious in-  
jury or death.  
l Never carry riders in cargo  
box.  
7077681  
TRAILER MAX.  
WEIGHT 1500 LBS.  
HITCH MAX. VERTICAL  
WEIGHT 150 LBS.  
7077682  
IMPROPER TIRE PRESSURE OR OVER-  
LOADING CAN CAUSE LOSS OF CONTROL.  
LOSS OF CONTROL CAN RESULT IN  
SEVERE INJURY OR DEATH.  
TIRE PRESSURE (PSI):  
FRONT MIN. 5 MAX. 12  
CENTER & REAR MIN. 5 MAX. 10  
MAXIMUM WEIGHT CAPACITY  
(Gross Vehicle Weight)  
INCLUDING MACHINE, PASSENGER  
AND CARGO IS 2920 LBS.  
SEE OWNER’S MANUAL FOR PROPER  
TIRE INFLATION FOR DIFFERENT VEHICLE  
APPLICATIONS.  
7077475  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
HEADLAMPS ARE NOT SEALED.  
DO NOT SUBMERGE OR APPLY  
WATER PRESSURE DIRECTLY ONTO  
SERVICE OPENING.  
Recoil handle must be firmly seated to  
prevent water entry. Drain starter motor  
if water enters. See owner’s manual.  
7075741  
WARNING/AVERTISSEMENT  
This vehicle is designed for operator and  
“ONE” passenger only  
Ce Vehicule est concu pour ne transporter  
que le conducteur et “UN SEUL” passager.  
7075439  
WARNING  
DO NOT ATTEMPT ENGINE OR  
CLUTCH MODIFICATION. DOING SO  
CAN CAUSE IMBALANCE AND/OR  
EXCESSIVE ENGINE RPM.  
EXCESSIVE ENGINE RPM CAN CAUSE  
PART FAILURE RESULTING IN  
POSSIBLE SEVERE INJURY OR  
DEATH.  
DO NOT MODIFY ENGINE OR CLUTCH.  
7077377  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
7077683  
Text found below  
OPERATOR/LOAD DISTRIBUTION WARNINGS  
VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSS  
OF CONTROL AND RESULT IN SEVERE INJURY OR DEATH.  
MAKE STARTS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTH  
MANNER so as not to shift the load or overturn the vehicle.  
THE FOOT BRAKE PEDAL CONTROLS THE PRIMARY BRAKING for this ve-  
hicle.  
THE PARK/EMERGENCY BRAKE LEVER will supply increased braking, but  
should be used as an EMERGENCY OR PARKING BRAKE ONLY.  
THE BOX DUMP LATCH MUST BE SECURELY LATCHED before loading and op-  
erating. Unintentional box dumping will result if weight is placed in the rear of the  
box and the latch is not secured.  
NEVER OPERATE THIS VEHICLE WITH THE DUMP BOX IN THE RAISED  
POSITION. The dump box could close unexpectedly while driving, severely injur-  
ing the driver and passenger. The rear tires will catch the rear of the box, damaging  
the vehicle and creating hazardous driving conditions.  
THE VEHICLE BRAKING PERFORMANCE IS REDUCED WHEN CARRYING  
LOADS. Reduce speeds and allow for greater stopping distances when operating  
in a loaded or trailering condition.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
THE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING IN  
A LOADED CONDITION on rough or hilly terrain. When climbing hills always hav-  
ing the cargo in the rear box securely fastened and located as far forward in the box  
as possible. Loaded vehicles will experience reduced steering and front brake ef-  
fectiveness when operating on hills.  
TO REDUCE THE CHANCE OF VEHICLE TIP-OVER AND PERSONAL INJURY  
always use D-1 Gear and reduced vehicle speeds when carrying heavy loads or  
towing a loaded trailer.  
Correct loading of this vehicle is necessary to maintain proper stability and operat-  
ing characteristics. Overloading or incorrect positioning of the load effects the ve-  
hicles turning, stopping distance and stability. Failure to follow loading require-  
ments could cause severe injury or death. REDUCE SPEED AND ALLOW  
GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.  
MAXIMUM CARGO CAPACITY IS 1000 LBS. ON LEVEL TERRAIN. When oper-  
ating over rough or hilly terrain, reduce speed and cargo to maintain stable driving  
conditions. When operating at maximum cargo capacity, the cargo weight must be  
evenly distributed in the rear box.  
ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured  
loads can create unstable operating conditions which could result in loss of control  
of the vehicle.  
LOADS MUST BE CARRIED AS LOW IN THE BOX AS POSSIBLE. Carrying  
loads high in the box raises the center of gravity of the vehicle and creates a less  
stable operating condition. When cargo loads are carried high in the box, the  
weight of the loads must be reduced to maintain stable operating conditions.  
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When han-  
dling off-centered loads which cannot be centered, securely fasten load and oper-  
ate with extra caution.  
EXTREME CAUTION MUST BE USED when operating with loads extending over  
the box sides. Stability and maneuverability may be adversely affected, causing  
the machine to overturn.  
SEE YOUR OWNER’S MANUAL.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
7077680  
Text found below  
READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFORE  
OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING  
WARNINGS OR IMPROPER USE. If you do not have the Owner’s Manual for this  
vehicle, call 1-800-324-3674 to have one provided at no extra charge.  
D
This vehicle REQUIRES SPECIAL RIDING SKILLS due to its handling.  
Ride within your skill.  
D
THIS VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A  
VALID DRIVER’S LICENSE. Operation by unlicensed operators increases  
the risk of severe injury or death.  
D
MINIMUM AGE RECOMMENDATION FOR PASSENGERS IF 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.  
D
D
THIS VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rol-  
lover can occur quickly, even during routine maneuvers such as turning, driv-  
ing on hills or over obstacles, if you fail to take proper precautions.  
TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN EN-  
COUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS  
OR DURING TURNS.  
D
D
KEEP FEET ON FLOORBOARDS AT ALL TIMES.  
ALWAYS FASTEN YOUR SEATBELTS SECURELY AROUND YOU.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY WARNING AND OPERATION DECALS  
D
OPERATION ON HILLS IS DANGEROUS, especially when loaded. This  
vehicle is designed for utility usage on moderate terrains. Turning, braking  
and uneven terrain can induce rollovers especially if a maneuver is abrupt.  
Under no circumstances should you climb, descend or traverse hills greater  
than 15°∠. Vehicle stability is greatly reduced during operating on hills,  
creating the possibility of vehicle rollover and serious injury, including death  
or paralysis. Extreme caution should be used when operating this vehicle on  
any side hill conditions. Effectiveness of brakes is significantly reduced on  
hills. Some hills are too steep to safely stop or recover from an unsuccessful  
climbing attempt. If vehicle slides backwards down hill, apply brakes with  
gradual, even pressure and do not apply the throttle. Sudden or aggressive  
application of brakes may cause loss of control.  
D
D
REDUCE SPEED when operating this vehicle on rough or hilly terrain, or  
when carrying cargo.  
OFF-ROAD USE ONLY. Never operate on public roads as severe injury or  
death may occur - this vehicle is not built for legal operation of public roads.  
Always avoid paved surfaces.  
D
D
D
NEVER OPERATE THIS VEHICLE AT EXCESSIVE SPEEDS. You in-  
crease your risk of losing control if you operate this vehicle at speeds too fast  
for the terrain, visibility conditions, or your experience.  
HELMETS ARE RECOMMENDED WHENEVER DRIVING THIS VEHICLE  
IN AN AGGRESSIVE MANNER. Eye protection is recommended at all  
times. (See Owner’s Manual)  
REVERSE OPERATION CAN BE DANGEROUS. Steering control becomes  
difficult. When backing up, proceed slowly and apply brakes carefully;  
aggressive braking may result in loss of control. Avoid backing downhill.  
avoid turning at sharp angles in reverse.  
D
D
STOPPING DISTANCE MAY INCREASE WITH WET BRAKES OR ON  
WET SURFACES.  
VEHICLE DESIGNED MAINLY FOR WARM WEATHER USE. Throttle link-  
age and brakes may stick if operated in freezing weather, causing loss of  
control. Dirt mud, water or other contaminants can also affect operation of  
controls. Check both frequently.  
D
D
D
D
High speeds, jumps and stunts are dangerous and could result in loss of  
control and other accidents.  
NEVER PERMIT A GUEST TO OPERATE THIS VEHICLE unless the guest  
has read the Owner’s Manual and all labels.  
NEVER USE ALCOHOL OR DRUGS before or while operating the vehicle.  
They slow reaction time and impair judgement.  
SEVERE INJURY OR DEATH can result if you do not follow these instruc-  
tions.  
CAUTION: Do not shift while vehicle is moving.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
LABEL LOCATION  
4
1
3
5
2
6
1. Warning (General)  
2. Warning (Vehicle roll-over)  
3. Warning (Load Distribution)  
4. Warning (Cargo Bed)  
5. Tire Pressure  
6. Towing Information  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
DAILY PRE-RIDE INSPECTION  
Inspect your vehicle each time before riding to ensure it is in proper working  
order. If proper inspection is not done, severe injury or death could result.  
WARNING  
If a proper inspection is not performed serious injury or death can result.  
Always inspect your RANGER before riding following the checklist care-  
fully.  
Before riding your vehicle, inspect all operating controls and parts.  
Item/Inspection Procedure  
1. Tires - check condition and pressures  
2. Fuel and oil tanks - fill both tanks to their proper levels  
3. All brakes - check operation, adjustment and fluid level (includes  
emergency/parking brake)  
4. Throttle - check for free operation and closing  
5. Headlight/Taillight/Brakelight - check operation of all indicator lights  
and switches  
6. Engine ignition switch - check for proper function  
7. Wheels - check for tightness of wheel nuts and axle nuts; check that  
axle nuts are secured by cotter pins  
8. Air cleaner element - check for dirt; clean or replace  
9. Steering - check for free operation noting any unusual looseness in  
any area  
10. Loose parts - visually inspect vehicle for any damaged or loose nuts/  
bolts or fasteners  
11. Operator and passenger should be properly dressed.  
12. Engine coolant - check for proper level at the recovery bottle.  
13. Check condition and operation of the dump box/bed latch mecha-  
nism.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle without proper instruction.  
WHAT CAN HAPPEN  
The risk of an accident is greatly increased if the operator does not know  
how to operate the vehicle properly in different situations and on differ-  
ent types of terrain.  
HOW TO AVOID THE HAZARD  
Read and understand the Owner’s Manual and all warning and instruc-  
tion labels on the vehicle.  
WARNING  
POTENTIAL HAZARD  
Failure to follow the age recommendations for this vehicle.  
WHAT CAN HAPPEN  
Use of this vehicle by a child can lead to severe injury or death of the child  
or others.  
Even though a child may be within the age group for which some vehicles  
are recommended, he or she may not have the skills, abilities, or judg-  
ment needed to operate the vehicle safely and may be involved in a seri-  
ous accident.  
HOW TO AVOID THE HAZARD  
No one without a valid driver’s license should operate a PolarisRANGER.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle on paved surfaces.  
WHAT CAN HAPPEN  
This vehicle’s tires are designed for off-road use only; not for use on  
pavement. Paved surfaces may seriously affect handling and control  
of the vehicle, and may cause the vehicle to go out of control.  
HOW TO AVOID THE HAZARD  
Always avoid operating the vehicle on any paved surfaces, including  
sidewalks, driveways, parking lots and streets.  
WARNING  
Safe operation of this vehicle requires good judgement and physical  
skills. Persons with cognitive or physical disabilities who operate this  
vehicle have an increased risk of overturns and loss of control which  
could result in serious injury or death.  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle on public streets, roads or highways.  
WHAT CAN HAPPEN  
You can collide with another vehicle.  
HOW TO AVOID THE HAZARD  
Never operate this vehicle on any public street, road or highway, in-  
cluding dirt or gravel.  
In many states it is illegal to operate vehicles of this type on public  
streets, roads and highways.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
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  
Never consume alcohol or drugs before or while driving this vehicle.  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle at excessive speeds.  
WHAT CAN HAPPEN  
Increases your chances of losing control of the vehicle, which can  
result in an accident.  
HOW TO AVOID THE HAZARD  
Always travel at a speed which is proper for the terrain, visibility and  
operating conditions; and your experience.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Failure to inspect the vehicle before operating.  
Failure to properly maintain the vehicle.  
WHAT CAN HAPPEN  
Increases the possibility of an accident or equipment damage.  
HOW TO AVOID THE HAZARD  
Always inspect your RANGER each time you use it to make sure it  
is in safe operating condition.  
Always follow the inspection and maintenance procedures and  
schedules described in the Owner’s Manual.  
WARNING  
POTENTIAL HAZARD  
Attempting jumps and other stunts.  
WHAT CAN HAPPEN  
Increases the chance of an accident, including an overturn.  
HOW TO AVOID THE HAZARD  
Never attempt stunts such as jumps. Don’t try to show off.  
WARNING  
POTENTIAL HAZARD  
Failure to use extra care when operating this vehicle on unfamiliar terrain.  
WHAT CAN HAPPEN  
You can come upon hidden rocks, bumps, or holes, without enough time  
to react.  
Could result in the vehicle overturning or going out of control.  
HOW TO AVOID THE HAZARD  
Go slowly and be extra careful when operating on unfamiliar terrain.  
Always be alert to changing terrain conditions when operating the vehicle.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Failure to use extra care when operating on excessively rough, slip-  
pery or loose terrain.  
WHAT CAN HAPPEN  
Could cause loss of traction or vehicle control, which could result in  
an accident, including an overturn.  
HOW TO AVOID THE HAZARD  
Do not operate on excessively rough, slippery or loose terrain until  
you have learned and practiced the skills necessary to control the ve-  
hicle on such terrain.  
Always be especially cautious on these kinds of terrain.  
WARNING  
POTENTIAL HAZARD  
Operating on excessively steep hills.  
WHAT CAN HAPPEN  
The vehicle can overturn more easily on extremely steep hills than on  
level surfaces or small hills.  
HOW TO AVOID THE HAZARD  
Never operate the RANGER on hills too steep for the vehicle or for your  
abilities.  
Practice on smaller hills before attempting large hills.  
Never operate vehicle on hills steeper than 15_ .  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Climbing hills improperly.  
WHAT CAN HAPPEN  
Could cause loss of control or cause vehicle to overturn.  
HOW TO AVOID THE HAZARD  
Always check the terrain carefully before you start up any hill.  
Never climb hills with excessively slippery or loose surfaces.  
Never open the throttle suddenly. The vehicle could go out of control.  
Never go over the top of any hill at high speed. An obstacle, a sharp  
drop, or another vehicle or person could be on the other side of the hill.  
WARNING  
POTENTIAL HAZARD  
Going down a hill improperly.  
WHAT CAN HAPPEN  
Could cause loss of control or cause vehicle to overturn.  
HOW TO AVOID THE HAZARD  
Always check the terrain carefully before you start down any hill.  
Never go down a hill at high speed.  
Avoid going down a hill at an angle which would cause the vehicle to  
lean sharply to one side. Go straight down the hill where possible.  
WARNING  
POTENTIAL HAZARD  
Improperly crossing hills or turning on hills.  
WHAT CAN HAPPEN  
Could cause loss of control or cause vehicle to overturn.  
HOW TO AVOID THE HAZARD  
Be very careful when turning on any hill.  
Avoid crossing the side of a steep hill if possible.  
When crossing the side of a hill:  
Avoid hills with excessively slippery or loose surfaces.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Improperly operating over obstacles.  
WHAT CAN HAPPEN  
Could cause loss of control or a collision. Could cause vehicle to overturn.  
HOW TO AVOID THE HAZARD  
Before operating in a new area, check for obstacles.  
Use extreme caution when riding over large obstacles, such as large rocks  
or fallen trees.  
WARNING  
POTENTIAL HAZARD  
Skidding or sliding.  
WHAT CAN HAPPEN  
You may lose control of the vehicle.  
You may also regain traction unexpectedly, which may cause the vehicle  
to overturn.  
HOW TO AVOID THE HAZARD  
On slippery surfaces, such as ice, go slowly and be very cautious in order  
to reduce the chance of skidding or sliding out of control.  
WARNING  
POTENTIAL HAZARD  
Riding on frozen lakes and rivers.  
WHAT CAN HAPPEN  
Severe injury or death can result if the vehicle and/or the operator break  
through the ice.  
HOW TO AVOID THE HAZARD  
Never ride your RANGER on a frozen body of water before you are sure  
the ice is thick enough and sound enough to support the machine and its  
operator, as well as the force that is created by a moving vehicle.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle through deep or fast flowing water.  
WHAT CAN HAPPEN  
Tires may float, causing loss of traction and loss of control, which  
could lead to an accident.  
HOW TO AVOID THE HAZARD  
Never operate this vehicle in fast flowing water or in water deeper than  
that specified in your Owner’s Manual. See page 52.  
Remember that wet brakes may have reduced stopping ability. Test  
your brakes after leaving water. If necessary, apply them several  
times to let friction dry out the pads.  
WARNING  
POTENTIAL HAZARD  
Improperly operating in reverse.  
WHAT CAN HAPPEN  
You could hit an obstacle or person behind you, resulting in serious injury.  
HOW TO AVOID THE HAZARD  
Before you select reverse gear, make sure there are no obstacles or  
people behind you. When it is safe to proceed, go slowly. Always avoid  
backing down hill.  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle with improper tires, or with improper or uneven  
tire pressure.  
WHAT CAN HAPPEN  
Use of improper tires on this vehicle, or operation of this vehicle with  
improper or uneven tire pressure, may cause loss of control, and in-  
creases the risk of an accident.  
HOW TO AVOID THE HAZARD  
Always use the size and type tires specified in the Owner’s Manual for  
this vehicle. See page 91.  
Always maintain proper tire pressure as described in the Owner’s  
Manual. See page 2.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this vehicle with improper modifications.  
WHAT CAN HAPPEN  
Improper installation of accessories or modification of this vehicle may cause  
changes in handling which in some situations could lead to an accident.  
HOW TO AVOID THE HAZARD  
Never modify this vehicle through improper installation or use of accessories.  
All parts and accessories added to this vehicle should be genuine Polaris In-  
dustries Inc. or equivalent components designed for use on this vehicle; and  
should be installed and used according to instructions. If you have questions,  
consult an authorized Polaris dealer.  
WARNING  
POTENTIAL HAZARD  
Stalling, rolling backwards while climbing a hill.  
WHAT CAN HAPPEN  
Could result in vehicle overturning.  
HOW TO AVOID THE HAZARD  
Maintain steady speed when climbing a hill.  
If you lose all forward speed:  
Apply the brakes.  
Lock parking brake after you are stopped.  
If you begin rolling backwards:  
Never apply engine power.  
Apply the brake gradually.  
When fully stopped, lock parking brake.  
In the event of an accident, have a qualified service dealer check the com-  
plete machine including, but not limited to brakes, throttle and steering for  
possible damage.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Overloading this vehicle or carrying or towing cargo improperly.  
WHAT CAN HAPPEN  
Could cause changes in vehicle handling which could lead to an accident.  
HOW TO AVOID THE HAZARD  
Never exceed the stated load capacity for this vehicle.  
Cargo should be properly distributed and securely attached.  
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-  
tance for braking.  
Always follow the instructions in the Owner’s Manual for carrying cargo or  
pulling a trailer. See page 45.  
WARNING  
Never carry passengers in the box.  
If the weight distribution on the box is located toward the rear of the box  
and the release lever is pulled forward, the box will want to dump on its  
own. Never operate the dump lever without checking the position of  
the load. This will prevent unexpected dumping of the cargo box.  
WARNING  
In the event of an accident have a qualified service dealer check the  
complete machine including, but not limited to, brakes, throttle, and  
steering for possible damage.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VEHICLE IDENTIFICATION NUMBERS  
1
Important: Record these numbers from your vehicle in the spaces provided.  
1. Frame VIN:  
2. Vehicle Model Number:  
3. Engine Serial Number (Right front side of engine crankcase)  
Remove the spare key and store in a safe place. Record your ignition key num-  
ber here. It is a four digit number found stamped on the key. In the event the  
key is lost, replacement can be made by supplying your dealer with this number.  
Ignition Key Number  
The vehicle frame and engine serial numbers are important for model identifica-  
tion when registering your vehicle, obtaining insurance or whenever replace-  
ment parts are required. In the event your vehicle were stolen these numbers  
are essential to the recovery and identification of your vehicle.  
Dealer Imprint  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
Fuel Gauge  
The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank.  
When the red indicator needle comes near the E (empty) mark, refuel at the earliest  
opportunity.  
Ignition Switch  
This is a three-position, key-operated switch. The key can be removed from the  
switch when it is in the OFF position.  
OFF  
ON  
Engine off. All electrical circuits off except Acc. 12V.  
All electrical equipment can be used.  
START  
Electric starter is engaged by holding ignition switch key in  
this position. Upon release, the key will return to the ON  
position.  
Do not operate the starter continuously for more than 5 seconds, or the start-  
er will overheat and the battery power will drop temporarily. Wait at least 5 seconds  
between each operation of the starter to let it cool and the batter power recover.  
Do not turn the ignition switch key to the START position with the engine run-  
ning, or damage to the starter can result.  
Light Switch Lever  
Turn on headlights and taillights by flipping the light switch lever up, with the ignition  
switch key in the ON position.  
The lights go off when the lever is pushed down.  
4WD - AWD Rocker Switch  
This vehicle can be operated in either 4WD or AWD. The 4WD-AWD is operated  
by a rocker switch located on the console. Flipping the lever up will engage the  
AWD.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
Parking Brake Lever  
The parking brake lever is located at the right side of the driver’s seat. Pull the lever  
up and to the rear to apply the parking brake.  
To release, push in and hold the knob on the end of the lever and push the lever  
all the way down. Spring pressure helps return the lever to the released position.  
Auxiliary Lighting/Electrical  
Accessory Terminals  
The auxiliary lighting/electrical ac-  
cessory 12 volt terminals (1) are lo-  
cated under the instrument panel.  
An auxiliary light or other optional  
light, or an accessory may be con-  
nected to these terminals.  
Brake Pedal  
The brake pedal (2) is the left pedal  
on the foot board. Depress the  
brake pedal to slow or stop the ve-  
hicle.  
1
WARNING: Once a bottle of brake  
fluid is opened, use what is neces-  
sary and discard the rest. Do not  
store or use a partial bottle of brake  
fluid. Brake fluid is hygroscopic,  
meaning it rapidly absorbs moisture  
from the air. This causes the boiling  
temperature of the brake fluid to  
drop, which can lead to early brake  
fade and the possibility of serious in-  
jury.  
2
Braking  
NOTE: Practice starting and stopping (using the brakes) until you are familiar with  
the controls.  
NOTE: When the throttle pedal is released completely and the engine speed drops  
near an idle, the vehicle has no engine braking.  
1. Release the throttle pedal completely  
2. Press on the brake pedal evenly and firmly.  
WARNING  
Be sure to apply the parking brake before leaving the vehicle. If the vehicle  
moves, it might be damaged or cause injury.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
Seat Belts  
The vehicle is equipped with lap-style seat belts for the operator and passenger.  
WARNING  
Seat belts reduce injury. Always were your seat belt. Minimum age recommen-  
dation for passengers if five years old. Passengers under five years of age re-  
quire special restraints which are not available with this vehicle.  
To wear the seat belt properly, follow this procedure:  
1. Place the belt across your lap as low on your hips as possible taking care that  
the belt is not twisted.  
2. Push the latch plate into the buckle until it clicks.  
3. Release the strap, it will self tighten.  
To unfasten the belt, press on the squared red button in the center of the buckle.  
Steering Wheel  
The steering wheel position can be  
adjusted to suit the operator.  
1. Loosen the bolt and nut (1) on the  
steering column bracket and  
move the steering wheel up or  
down to desired height.  
2. Tighten the bolts and nuts.  
1
Throttle Pedal  
The throttle pedal is the right pedal on the floor board. Push the pedal down to in-  
crease engine speed. Spring pressure returns the pedal to the rest position when  
released. Always check that the throttle pedal returns normally before starting the  
engine. In addition, there must be adequate throttle pedal play. Refer to page 76  
for throttle pedal adjustment procedure.  
Trailer Hitch Bracket  
This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer tow-  
ing equipment is not supplied with this vehicle.  
To avoid injury and property damage, observe the precautions on page 45.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
Engine Fuel  
and Oil System  
The fuel tank filler cap (1) is lo-  
cated on the left side by the driv-  
ers seat. Use either leaded or un-  
leaded gasoline with a minimum  
pump octane number of 87 R+  
M/2 octane.  
The fuel supply valve (2), located  
in the center console storage  
compartment (A) has three posi-  
tions:  
1
OFF: For vehicle storage and  
whenever transporting.  
ON: For normal operation.  
RES: For reserve supply in the  
event of main supply exhaustion.  
NOTE: There is about a 7 to 10  
mile (11.2 to 16 km) range on re-  
serve gas. Always refill the gas  
tank as soon as possible after  
having used the reserve supply.  
Always return valve to “on” posi-  
tion after refueling machine.  
Gasoline and Alcohol  
Blends  
Blends of gasoline and alcohol  
called “gasohol” can be used on  
an occasional basis, however  
continued use is not recom-  
mended. Switch back immedi-  
ately to gasoline which does not  
contain alcohol if you experience  
any operating irregularities. Any  
deterioration of fuel system com-  
ponents or degradation of perfor-  
mance resulting from the use of  
gasohol will not be covered by  
Polaris’ Warranty.  
2
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
D
Always exercise extreme caution whenever handling gasoline.  
D
A
l
w
a
y
s
r
e
f
u
e
l
w
i
t
h
t
h
e
e
n
g
i
n
e
s
t
o
p
p
e
d
a
n
d
o
u
t
d
o
o
r
s
o
r
i
n
a
w
e
l
l
v
e
n
t
i
-
lated area.  
D
D
o
n
o
t
s
m
o
k
e
o
r
a
l
l
o
w
o
p
e
n
f
l
a
m
e
s
o
r
s
p
a
r
k
s
i
n
o
r
n
e
a
r
t
h
e
a
r
e
a
w
h
e
r
e
refueling is performed or where gasoline is stored.  
D
Do not over fill the tank. Do not fill the tank neck.  
D
I
f
y
o
u
s
h
o
u
l
d
g
e
t
g
a
s
o
l
i
n
e
o
n
y
o
u
r
s
k
i
n
o
r
c
l
o
t
h
i
n
g
,
i
m
m
e
d
i
a
t
e
l
y
w
a
s
h
it off with soap and water and change clothing.  
D Never start the engine or let it run in an enclosed area. Gasoline pow-  
ered engine exhaust fumes are poisonous and can cause loss of con-  
sciousness and death in a short time.  
D
Shut off fuel valve whenever the vehicle is stored or parked.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL PARTS AND FUNCTIONS  
WARNING  
The engine exhaust from this  
product contains chemicals  
known to cause cancer, birth de-  
fects or other reproductive harm.  
Never use gasohol with an octane rating lower than the minimum octane rat-  
ing specified for this product.  
Never use gasohol containing more than 10% ethanol (grain alcohol).  
Never use gasohol containing more than 5% methanol (wood alcohol). Gas-  
oline containing methanol must also be blended with cosolvents and corrosion in-  
hibitors.  
Never use gasohol for extended periods and never store this vehicle with  
gasohol in the fuel system.  
Gasoline containing alcohol can cause paint damage. Be extra careful not  
to spill gasohol during refueling.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
VEHICLE NOMENCLATURE - Left View  
2
1
7
4
3
6
5
9
10  
11  
8
1. Cab Frame  
2. Cab Frame Hand Hold  
3. Dashboard  
4. Steering Wheel  
5. Gear Shift Lever  
6. Seat  
7. Cargo Box  
8. Seat Belts  
9. Parking Brake  
10. Engine Compartment Access Panel  
11. Hood Latches (attached to hood; left and right sides under dash)  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
VEHICLE NOMENCLATURE - Front View  
13  
14  
12  
12  
12. Headlights  
13. Air Box (under hood)  
14. Battery (under hood)  
15. Radiator (under hood)  
16. Front Bumper/Brush Guard  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
VEHICLE NOMENCLATURE - Rear View  
17  
17  
18  
21  
20  
19  
17. Tail Gate Latches (Top and Bottom)  
18. Tail Gate  
19. Muffler (Spark Arrester)  
20. Trailer Hitch Receiver  
21. Taillight  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
VEHICLE NOMENCLATURE - Instrument Panel  
4
3
6
7
5
8
9
2
12  
11  
1
10  
1. Choke Knob  
2. Ignition Switch  
3. Hour Meter  
4. Passenger Warning Decal  
5. Neutral Indicator Light  
6. Reverse Indicator Light  
7. Brake Light  
8. Coolant Temperature Warning Light  
9. Fuel Gauge  
10. 12V Accessory Plug  
11. Fog/High Beam Light Switch  
12. AWD (All Wheel Drive) Switch  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Demand 6 Drive  
Exclusive Demand 6 Drive System (All Wheel Drive)  
This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 6 Drive  
(AWD) system which is activated by a switch on the dash. When the switch is “off”  
the RANGER is in 4 wheel drive at all times. When the switch is “on” the RANGER  
is in Demand 6 Drive and the front wheels will automatically engage anytime the  
rear wheels lose traction. When the rear wheels regain traction, the front wheels  
will automatically disengage.  
The AWD button position and a red AWD light indicates when the vehicle is in De-  
mand 6 Drive. There is no limit to the length of time the vehicle may remain in De-  
mand 6 Drive.  
The AWD switch may be turned on or off while the vehicle is moving. If the switch  
is turned off when the front hubs are driving they will not release until the rear  
wheels regain traction.  
CAUTION: Do not switch on Demand 6 Drive if the rear wheels are spinning. This  
may cause severe drive shaft and clutch damage. Engage the Demand 6 Drive  
switch before getting into conditions where front wheel drive may be needed. If the  
rear wheels are spinning, release the throttle before turning the Demand 6 Drive  
switch on.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Transmission Gear Selector Operation  
The transmission gear selector is located to  
the right of the vehicle driver’s seat. The  
transmission selector lever has four posi-  
tions: high forward (D2); reverse; neutral;  
and low forward (D1).  
Shift Pattern  
D-2  
D-1  
Use of (low forward gear - D1) is recom-  
mended in heavy pulling situations to extend  
belt life.  
N
R
To change gears, stop the vehicle and with  
the engine idling, move the lever to the de-  
sired gear. Do not attempt to shift gears  
with engine speed above idle or while the  
vehicle is moving.  
Always place the transmission in gear with the parking brake locked whenever the  
vehicle is left unattended.  
Maintaining shift linkage adjustment is important to assure proper transmission  
function. Should you experience any shifting problem see your dealer.  
WARNING  
1. Do not attempt to shift the transmission while the vehicle  
is moving or while operating on hilly terrain.  
2. Always place the transmission in gear with the parking  
brake applied and turn the vehicle off whenever the ve-  
hicle is left unattended.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Disengaging Wheel Hubs  
When backing uphill while in Demand 6 Drive and then going forward downhill, one  
or both hubs may remain engaged. If one or both hubs remain engaged they can  
be disengaged by stopping, shifting to and moving in reverse. Then proceed in  
forward again.  
You can tell if only one front hub is engaged if the steering pulls to one side. If both  
front wheel hubs are engaged, steering effort increases but remains balanced from  
left to right, and vehicle speed is somewhat restricted.  
WARNING: If both hubs were engaged and only one released during opera-  
tion, loss of control could result. If you experience hub engaging symptoms, use  
the above disengaging technique before proceeding. Failure to disengage front  
hubs as directed above could result in severe injury or death.  
If the hubs remain engaged after following these instructions return the vehicle to  
your dealer for service.  
PVT System  
WARNING  
The PVT system rotates at high speeds, creating large amounts of force  
on clutch components. Extensive engineering and testing has been con-  
ducted to insure the safety of this product. However, as the owner you  
have the following responsibilities to make sure this system remains safe:  
D
Do not modify any component of the PVT system. Doing so may  
reduce its strength so that a failure may occur at high speeds. This  
system has been precision balanced. Any modification will cause the  
system to be out of balance, creating vibration and additional loads  
on components.  
D
Routine maintenance is the responsibility of the owner. Always fol-  
low recommended maintenance procedures. See your dealer!  
D
D
This PVT system is intended for use on Polaris products only.  
The PVT housing must be securely in place during operation.  
Failure to comply with this warning can result in severe injury or death.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Engine Cooling System  
Coolant Level  
The recovery bottle (1), located  
on the left side of the machine  
must be maintained between the  
minimum and maximum levels  
indicated on the recovery bottle.  
The engine coolant level is con-  
trolled or maintained by the re-  
covery system. The recovery  
system components are the re-  
covery bottle, radiator filler neck,  
radiator pressure cap and con-  
necting hose.  
1
As coolant operating tempera-  
ture increases, the expanding  
(heated) excess coolant is forced out of the radiator past the pressure cap and into  
the recovery bottle. As engine coolant temperature decreases the contracting  
(cooled) coolant is drawn back up from the tank past the pressure cap and into the  
radiator.  
NOTE: Some coolant level drop on new machines is normal as the system is purg-  
ing itself of trapped air. Observe coolant levels and maintain as recommended by  
adding coolant to the recovery bottle. Polaris recommends the use of Polaris Pre-  
mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com-  
patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is  
already premixed and ready to use. Do not dilute with water. NOTE: Always follow  
the manufacturer’s mixing recommendations for the freeze protection required in  
your area.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Engine Cooling System  
Radiator Coolant Level Inspection  
NOTE: This procedure is only required if the cooling system has been drained for  
maintenance and/or repair. However, if the recovery bottle has run dry, the level  
in the radiator should be inspected and coolant added if necessary.  
WARNING Never remove the pressure cap when the engine is warm or hot.  
Escaping steam can cause severe burns. The engine must be cool before remov-  
ing the pressure cap.  
Lift the hood and locate the radiator cap.  
NOTE: Use of a non-standard pressure cap will not allow the recovery system to  
function properly. If the cap should need replacement contact your dealer for the  
correct replacement part.  
Drain Plug  
Locations  
Crankcase Drain  
The oil should be changed annu-  
ally, especially before off season  
storage. If the machine is used  
in wet conditions the oil should  
be checked more frequently. If  
the oil has a milky appearance it  
should be changed as soon as  
possible. Failure to properly  
maintain this important area can  
result in premature wear or pos-  
sible failure of the engine com-  
ponents. Always use Polaris  
0W-40 oil.  
Recoil  
Drain  
Engine Access  
Panel Removal and  
Installation  
2
Engine access panels are re-  
moved by pulling handle out and  
then up (no tools are required).  
Install by firmly placing the bot-  
tom pins in the grommets and  
pushing the top pins (1) into the  
grommets (2).  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Engine Cooling System  
To insure that the coolant maintains its ability to protect the engine, it is recom-  
mended that the system be completely drained every two years and a fresh mixture  
of antifreeze and water be added. Polaris recommends the use of Polaris Pre-  
mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com-  
patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is  
already premixed and ready to use. Do not dilute with water. IMPORTANT: Al-  
ways follow the manufacturer’s mixing recommendations for the freeze protection  
required in your area.  
Using a funnel, slowly add coolant as necessary.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
4 Cycle Premium 4 Synthetic Lubricant  
Polaris Premium 4 All Season Synthetic engine oil has been specially formulated  
for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis-  
cosity oil designed to provide the ultimate in lubrication performance and protec-  
tion.  
Premium 4 possesses unsurpassed film strength over the widest possible temper-  
ature range. It resists viscosity and frictional breakdown in ambient temperatures  
from -40° F to 120° F. Its exceptional frictional properties result in more efficient  
operation, more power output and lower fuel consumption.  
Although Polaris Premium 4 is the only oil recommended for use in this engine, use  
of any API certified “SH” oil is allowable. Oil may need to be changed more fre-  
quently if Polaris Premium 4 is not used. You will also need to follow the manufac-  
turers recommendations for ambient temperature operation.  
Oil System  
The oil tank is located on the left side of the vehicle. To check the oil:  
1. Set machine on a level surface.  
2. Start the engine and let it  
idle for 20-30 seconds.  
3. Stop the engine, remove  
dipstick (1) and wipe dry  
with a clean cloth.  
4. Screw in the dipstick  
completely, remove it and  
read the oil level. NOTE:  
The dipstick must be  
screwed in to keep the  
angle and depth of stick  
consistent.  
2
5. Remove dipstick and check  
to see that the oil level is  
between the full and add  
marks. Add oil as indicated  
by the level on the dipstick.  
Do not overfill.  
CAUTION: Use only Polaris  
ADD 8 OZ.  
NORMAL  
FULL  
Premium 4 All Season synthetic  
oil (PN 2871271), or API certified  
“SH” oil. Never substitute or mix  
oil brands. Serious engine dam-  
age and voiding of warranty can  
result.  
Maintain Oil Level In Normal Range  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Oil and Filter Change  
The recommended oil change interval is 100 hours, 1000 miles, or every six  
months, whichever comes first. Suggested break in oil change is at 20 hours, 500  
miles, or one month, whichever comes first. Severe use operation requires more  
frequent service. Severe use includes continuous duty in dusty or wet conditions,  
and cold weather riding. NOTE: Severe use cold weather riding is all riding below  
10° F, and riding between 10° F and 30°F when most trips are slow speed and less  
than 5 miles. Be sure to change the oil filter whenever changing oil (Polaris PN  
3084963).  
1. Place vehicle on a level  
surface.  
2. Remove rear wheel well  
panel by cutting dart clips  
and removing screws.  
3. Clean area around drain  
plug at the bottom of the oil  
tank.  
4. Run engine for two to three  
minutes until warm. Shut  
engine off.  
5. Place a drain pan beneath  
the oil tank and remove the  
drain plug. CAUTION: Oil  
2
may be hot. Do not allow hot  
oil to come into contact with  
skin as serious burns may  
result.  
1
6. Allow oil to drain completely.  
7. Install a new sealing washer (PN 5850135) on oil drain plug. NOTE: The  
sealing surfaces on the drain plug and the oil tank should be clean and free of  
burrs, nicks or scratches.  
8. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)  
9. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter (1)  
counterclockwise to remove.  
10. Using a clean dry cloth, clean filter sealing surface on crankcase.  
11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make  
sure the O-Ring is in good condition. Also make sure the O-ring from the old  
filter is not still on the engine.  
12. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket contact.  
13. Approximately 1 cup of engine oil will remain in the crankcase. To drain,  
remove drain plug found on lower right side of crankcase. NOTE: The sealing  
surfaces on the drain plug and crankcase should be clean and free of burrs,  
nicks or scratches.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONTROL AND PARTS FUNCTIONS  
Oil and Filter Change (Cont.)  
14. Reinstall drain plug.  
15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.  
Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts  
initially.  
16. Place gear selector in neutral and set parking brake.  
17. Start engine and let it idle for one to two minutes. Stop engine and inspect for  
leaks.  
18. Re-check oil level on the dipstick and add oil as necessary to bring the level to  
the upper mark on the dipstick.  
19. Dispose of used filter and oil properly.  
Fuel Filter and Oil Filter  
Your Polaris RANGER is equipped with a unique in-line fuel filter.  
These filters should be replaced by your dealer after every 100 hours of operation  
or annually. Do not attempt to clean these filters.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
STARTING THE ENGINE  
Stopping the Engine  
1. Release the throttle pedal completely.  
2. Put the gear shift lever into (N) Neutral.  
3. Apply the parking brake to help prevent the vehicle from rolling.  
4. Turn the ignition switch key to the OFF position.  
Procedure for Starting a Cold Engine  
WARNING  
Do not start or operate this vehicle with sticking or improperly operating  
throttle pedal. A stuck or improperly operating throttle could cause an ac-  
cident resulting in severe injury or death.  
Always contact your dealer for service repairs whenever throttle prob-  
lems arise.  
Failure to check or maintain proper operation of the throttle system can  
result in the throttle pedal sticking during driving and cause an accident.  
Always check the pedal for free movement and return before starting the  
engine and occasionally during driving.  
1. Place the transmission in neutral and move the vehicle to a level surface.  
2. Lock the parking brake.  
3. Turn the fuel tank valve to ON.  
4. Sit in the vehicle in the driver’s seat.  
“FULL”  
“HALF”  
“OFF”  
Choke Lever Side View  
5. Move the choke lever to the FULL position.  
6. Turn the ignition key to START.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
STARTING THE ENGINE  
7. If engine does not start, release ignition switch and wait five seconds; then turn  
the ignition switch to start for another five seconds. Repeat this procedure until  
engine starts.  
NOTE: Do not press the throttle pedal while starting the engine.  
After the Engine Starts  
1. If the engine slows or stops, use of the choke lever at its HALF position will allow  
proper engine warm up.  
2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine  
idles smoothly. Then move the choke to OFF.  
CAUTION: Proper engine warm up is essential each time before driving to avoid  
engine damage.  
WARNING  
Carbon monoxide exhaust gas is poisonous!  
Always start the vehicle outdoors.  
Never run the engine in an enclosed area.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
STARTING THE ENGINE  
Procedure for Starting a Warm Engine  
Warm engines do not normally require the use of the choke since the spark plug  
can easily become wet fouled.  
1. Place the transmission in neutral and move the vehicle to a level surface.  
2. Lock the parking brake  
3. Turn the fuel tank valve to ON.  
4. Sit in the vehicle in the driver’s seat.  
5. Turn the ignition key to START.  
“HALF”  
6. If the engine has cooled to a point where it does not readily start, intermittent  
use of the choke lever in its HALF position is permitted.  
7. If the engine is over-choked by mistake when warm, depress the throttle lever  
fully while cranking to aid in starting.  
8. Release the throttle lever immediately after the engine starts. If the engine does  
not start and all conditions are favorable, change the spark plug.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
STARTING THE ENGINE  
Recoil Starter  
Recoil Starter  
If the battery is weak and cannot start the engine, use of the recoil starter located  
on the right side of the machine will allow vehicle operation until repairs can be  
made.  
1. Be certain the parking brake is set. See page 27.  
2. Remove right side engine access panel. See page 35.  
3. Grasp the recoil starter tightly and pull slightly until the starter mechanism en-  
gages.  
4. Pull the rope abruptly to start the engine. CAUTION: Take care not to extend  
the starter rope so far that it stops, causing damage to the recoil assembly.  
CAUTION: Never start the engine with the battery disconnected. Damage to the  
electrical system and lamps may result.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VEHICLE BREAK-IN PERIOD  
The break in period for your new Polaris RANGER is defined as the first twenty  
hours of operation, or the time it takes to use the first two tanks full of gasoline. No  
single action on your part is as important as a proper break in period. Careful treat-  
ment of a new engine will result in more efficient performance and longer life for the  
engine. Perform the following procedures carefully.  
CAUTION: Use only Polaris Premium 4 All Season synthetic oil, or API certified  
“SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding  
of warranty can result.  
1. Fill fuel tank with either unleaded or leaded fuel which has a minimum pump  
octane number of 87= (R+ M)/2.  
2. Check oil reservoir level in-  
dicated on dipstick. Add oil  
if necessary.  
3. Drive slowly at first. Select  
ADD 8 OZ.  
NORMAL  
FULL  
an area which is open and  
will give you room to famil-  
iarize yourself with vehicle  
operation and handling.  
Maintain Oil Level In Normal Range  
4. Vary the throttle positions. Do not operate at sustained idle. CAUTION: Do  
not operate at full throttle or high speeds for extended periods during the first  
three hours of use. Excessive heat can build up and cause damage to close  
fitted engine parts.  
5. Perform regular checks on fluid levels, controls and all important areas on the  
vehicle as outlined earlier on the daily pre-ride inspection checklist found on  
page 9.  
6. Pull only light loads.  
7. Break in oil and filter. Change at 20 hours or 500 miles.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CARRYING LOADS  
The RANGER has been designed to carry or tow a certain amount of load. Always  
read and understand the load distribution warnings listed on the warning labels.  
Never exceed the following weights.  
Maximum Capacities  
(Level Ground)  
Cargo Box  
RANGER - 1500 lbs. (681 kg)  
1000 lbs. (454 kg)  
Dumping the Cargo Box  
1. Select a level site to dump the cargo box. Do not attempt to dump or unload  
the vehicle while parked on an incline.  
2. Set the parking brake.  
3. Dismount the vehicle.  
4. Stand clear and pull the cargo box release mechanism lever forward. Lift the  
front of the cargo box to dump.  
Maximum Towing Capacities (Level Ground)  
Maximum towed load weight - 1500 lbs. (681 kg) on level ground only; 850 lbs. (386  
kg) up to 15° grade. Maximum vertical hitch weight - 150 lbs (68.1 kg).  
Use of low forward is recommended in heavy pulling situations to extend belt life.  
Maximum grade while trailer towing - 15°; do not tow any trailer on a grade steeper  
than 15°.  
Total Towed  
Load Weight  
(level ground)  
Total Towed  
Load Weight (15°  
grade)  
Total Hitch  
Vertical Weight  
Towing  
Speed  
1500 lbs. (681 kg)  
850 lbs. (386 kg)  
150 lbs (68.1 kg)  
10 mph (16 kph) or less  
Do not carry more than 1000 Lbs. (454 kg) in the cargo box.  
WARNING  
Never carry a passenger in a trailer  
Never load more than 150 lbs (68.1 kg) tongue weight on the towing bracket.  
Do not operate the vehicle faster than 10 mph (16 km/h) when towing. Remem-  
ber that towing a trailer increases braking distance.  
Do not tow more than 1500 lb (681 kg) trailer weight(trailer plus cargo weight).  
Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any oth-  
er location or you may lose control of the vehicle and have an accident.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Load Distribution  
1. Always load the cargo box placing the load as far forward as possible.  
2. Always operate the vehicle with extreme care whenever hauling or towing  
loads.  
3. Slow down and drive in D-1 only.  
4. The cargo box dump latch must be securely latched before loading and operat-  
ing. Unintentional box tilting will result if weight is placed in the rear of the box  
and the latch is not secured.  
WARNING: Never operate this vehicle with the cargo box in the raised position.  
The cargo box could close unexpectedly while driving, severely injuring the driver.  
The rear tires will catch the rear of the box, damaging the vehicle and creating haz-  
ardous driving conditions.  
Do not carry more than 1000 Lbs. in the cargo box.  
Parking the RANGER  
1. Stop the vehicle on a level surface.  
CAUTION: Avoid parking on steeply inclined surfaces.  
2. When the engine has stopped, apply the parking brake to help prevent the ve-  
hicle from rolling  
WARNING  
Be sure to apply the parking brake before leaving the vehicle. If the vehicle  
should move, it might be damaged or cause injury.  
3. Remove the ignition switch key to prevent unauthorized use.  
NOTE: When parking inside a garage or other structure, be sure the structure is  
well ventilated and the vehicle is not close to any source of flame or sparks. This  
includes any appliance with a pilot light.  
WARNING  
Gasoline is extremely flammable and can be explosive under certain condi-  
tions.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
1. Sit in the driver’s seat with the seatbelt fastened.  
2. After starting the engine and allowing it to warm up, shift the transmission into  
gear.  
3. Check your surroundings and determine your path of travel.  
4. Release the parking brake.  
5. Keeping both hands on the steering wheel, slowly depress the throttle with your  
right foot and begin driving. Vehicle speed is controlled by the amount of  
throttle opening and PVT shifting is done automatically.  
6. Drive slowly, practice maneuvering and using the throttle and brakes on level  
surfaces.  
indicates a potential hazard which  
could result in serious injury or death.  
WARNING  
Load Distribution  
WARNING  
When carrying cargo or towing a trailer, remember that load weight will in-  
crease braking distances. Failure to allow for increased braking distance  
may result in accident and injury.  
1. Always load the cargo bed placing the load as far forward as possible.  
2. Always operate the vehicle with extreme care, especially when hauling or tow-  
ing loads.  
3. Slow down and drive in D-1 Gear only.  
4. The cargo box dump latch must be securely latched before loading and operat-  
ing. Unintentional box tilting can result if weight is placed in the rear of the box  
and the latch is not secured.  
5. Do not place loads on the cab frame  
WARNING: Never operate this vehicle with the cargo box in the raised position.  
The cargo box could close unexpectedly while driving, severely injuring the driver  
or passenger. The rear tires can catch the rear of the box, damaging the vehicle  
and creating hazardous driving conditions.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Riding On Slippery Surfaces  
Whenever driving on slippery surfaces such as wet trails or loose  
gravel, or during cold freezing weather, special attention must be  
paid to prevent vehicle turnover. Always:  
1. Slow down when entering slippery areas.  
2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp  
turns which can cause skids.  
3. Correct a skid by turning the steering wheel in the direction of the skid.  
4. Driving with Demand 6 Drive (All Wheel Drive) engaged can assist in control-  
ling the vehicle in slippery areas. CAUTION: Never engage Demand Drive  
while wheels are spinning as severe damage to drive train may occur.  
Before operating your vehicle on a frozen body of water be sure that the ice is thick  
enough to support the machine and its operator, as well as the force that is created  
by a moving vehicle. Severe injury or death can result if the vehicle and/or its oper-  
ator break through the ice.  
WARNING  
Failure to exercise care when operating on slippery surfaces can be dan-  
gerous.  
Loss of tire traction and vehicle control can result in an accident, including  
an overturn.  
D
D
D
Never apply brakes during a skid. Complete loss of control can result.  
Do not operate on excessively slippery surfaces if possible.  
Always reduce speed and use additional caution.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Operating on Hills  
WARNING  
Improperly crossing hills or turning on hills can be dangerous!  
Loss of vehicle control or overturning of the vehicle could occur.  
D
D
Avoid crossing the side of a steep hill if possible.  
Use extreme care when operating your RANGER in hilly terrain.  
Whenever descending a hill always:  
1. Drive directly downhill.  
2. Slow down.  
3. Apply the brakes lightly to aid in slowing.  
WARNING  
Loss of vehicle control due to excessive speed can occur. Loss of control  
may result in serious injury or death.  
Whenever traveling uphill always travel straight uphill and:  
1. Avoid steep hills.  
2. Keep both feet on the footrests.  
3. Proceed at a steady rate of speed and throttle opening.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
indicates a potential hazard which  
could result in serious injury or death.  
WARNING  
WARNING  
Braking and handling are greatly affected whenever operating in hilly ter-  
rain.  
Loss of vehicle control or overturning of the vehicle could occur.  
D
Avoid climbing steep hills (15_ maximum).  
D
Use extreme care when operating your vehicle in hilly terrain.  
WARNING  
Avoid climbing steep hills.  
Loss of vehicle control or overturning of vehicle could occur.  
D
Use extreme care when operating your RANGER in hilly terrain.  
WARNING  
Improperly crossing hills or turning on hills could cause loss of control or  
cause the vehicle to overturn.  
If at all possible, avoid crossing the side of a steep hill. Avoid hills with ex-  
cessively slippery or loose surfaces.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
WARNING  
Going down a hill improperly could cause loss of control or cause the ve-  
hicle to overturn.  
Always check the terrain carefully before you start down any hill.  
Never go down a hill at high speed.  
Avoid going down a hill at an angle which would cause the vehicle to lean  
sharply to one side. Go straight down the hill where possible.  
WARNING  
Climbing hills improperly can cause loss of control or cause vehicle to over-  
turn.  
Always check the terrain carefully before you start up any hill.  
Never climb hills with excessively slippery or loose surfaces.  
Never open the throttle suddenly. The vehicle could go out of control.  
Never go over the top of any hill at high speed. An obstacle, a sharp drop,  
or another vehicle or person could be on the other side of the hill.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Crossing Streams  
Your Polaris RANGER can operate through water up to depths reaching the floor-  
boards. Before fording streams always:  
1. Determine water depths and current.  
2. Choose a crossing where both banks have gradual inclines.  
3. Proceed slowly, avoiding rocks and obstacles if possible.  
4. After crossing, dry the brakes by applying light pressure to the lever until brak-  
ing action is normal.  
Should your vehicle become immersed, it will be necessary to take it to your dealer  
as soon as possible. Do not start the engine! Immersion of the vehicle can cause  
major damage if not correctly repaired.  
WARNING  
Never try to cross any deep or fast flowing streams.  
The large tires can cause the vehicle to float resulting in loss of control.  
D
Determine stream depth and speed before crossing.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Trail Obstacles  
Keep Alert!  
Look ahead and learn to read the trail as you ride. Stay on the right side of the trail,  
if possible, and be constantly alert for hazards such as logs, rocks and low hanging  
branches.  
WARNING  
Hidden or unseen hazards on the trail can be dangerous.  
Personal injury or the vehicle overturning can occur from unseen obstacles.  
D
Keep alert and constantly look for obstacles on the trail.  
indicates a potential hazard which  
could result in serious injury or death.  
WARNING  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Backing Up  
1. When backing up, always avoid backing downhill.  
2. Back slowly.  
3. When in reverse, apply the brakes lightly for stopping.  
4. Avoid turning at sharp angles in reverse.  
5. Never open the throttle suddenly while backing.  
6. Always inspect left and right fields of vision before backing.  
WARNING  
Backing your RANGER can be dangerous! You could hit an obstacle or  
person behind you; or the vehicle could tip over on a steep incline.  
D
Always back slowly, avoiding excessive speed.  
Avoid backing on steep inclines.  
D
Parking On An Incline  
Whenever the Vehicle is Parked  
1. Place the transmission in gear.  
2. Set the parking brake.  
3. Avoid parking on an incline. If it is necessary to park on an incline, always block  
the rear wheels on the down hill side.  
4. Shut off fuel supply.  
WARNING  
Always check to be sure that the parking brake has been disengaged  
before operating the vehicle. An accident could result if the parking  
brake is left on while the vehicle is operated.  
Always block the downhill side of the wheels if leaving the vehicle on  
a hill or park the vehicle in a side hill position.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATING SAFETY  
Dumping the Cargo Box  
1. Select a level site to dump the  
cargo box. Do not attempt to  
dump or unload the vehicle  
while parked on an incline.  
2. Set the parking brake.  
3. Dismount the vehicle.  
4. Stand clear and pull the cargo  
box release mechanism lever  
(1) forward. Lift the front of  
the cargo box to dump.  
1
WARNING  
If the weight distribution on the box is located toward the rear of the box  
and the release lever is pulled forward, the box will want to dump on its  
own. Never operate the dump lever without checking the position of  
the load. This will prevent unexpected dumping of the cargo box.  
WARNING  
Never carry passengers in the box.  
WARNING  
In the event of an accident have a qualified service dealer check the  
complete machine including, but not limited to, brakes, throttle, and  
steering for possible damage.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOISE EMISSION CONTROL SYSTEM REGULATION  
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!  
U.S. Federal law prohibits the following acts or the causing thereof:  
(1) The removal or rendering inoperative by any person other than for purposes of  
maintenance, repair, or replacement of any device or element of design incorpo-  
rated into any new vehicle for the purpose of noise control prior to its sale or delivery  
to the ultimate purchaser or while it is in use or  
(2) the use of the vehicle after such device or element of design has been removed  
or rendered inoperative by any person.  
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE  
ACTS LISTED BELOW.”  
1. Removal or alteration or the puncturing of the muffler or any engine component  
which conducts removal of engine exhaust gases.  
2. Removal or alteration or the puncturing of any part of the engine air induction  
system.  
3. Replacement of any vehicle parts with parts not in compliance with federal reg-  
ulations.  
4. Lack of proper maintenance.  
CAUTION: Remember, exhaust system components are very hot during and after  
use of the vehicle.  
D
Do not touch hot exhaust system components. Serious burns can result.  
D
Be especially careful when traveling through tall grass. The potential for fire  
exists.  
USFS Approved Spark Arrestor  
The muffler on this vehicle was tested and approved in accordance with the USFS  
Forest Service Standard 5100-1A.  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
BATTERY  
Battery  
CAUTION  
Whenever removing the battery, discon-  
nect the negative (black) cable first. When  
reinstalling the battery, connect the nega-  
tive (black) cable last.  
Maintain  
between  
upper and  
lower level  
marks  
Replenishing the Battery Fluid  
A poorly maintained battery will deteriorate  
rapidly. Check the battery fluid level often.  
The fluid level should be kept between the  
upper and lower level marks.  
To refill use only distilled water. Tap  
water contains minerals which are harmful  
to a battery.  
Battery Connections  
Battery terminals and connections should be kept 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 rags. Coat the terminals with dielectric grease or petro-  
leum jelly.  
Do not allow cleaning solution or tap water to enter the battery. It will shorten  
the life of the battery.  
Vehicle lamps may burn out if battery is disconnected during vehicle opera-  
tion. Also, the reverse speed limiter can be damaged.  
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 magne-  
sia, 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.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
BATTERY  
Battery Removal  
1. Disconnect hold down straps  
holding the battery (1) in position  
and remove battery retainer.  
1
2. Remove the battery vent tube  
from the battery.  
3. Disconnect the black (negative)  
battery cable first.  
4. Disconnect the red (positive) bat-  
tery cable next.  
5. Lift the battery out of the vehicle,  
being careful not to tip it sideways  
and spill any electrolyte.  
CAUTION: If electrolyte spills, immediately wash it off with a solution of one table-  
spoon baking soda and one cup water to prevent damage to the RANGER.  
Battery Installation  
WARNING: To avoid the possibility of explosion, always connect battery cables  
in the order specified. Red (positive) cable first; black (negative) cable last.  
1. Set the battery in its holder.  
2. Install the battery vent tube. It must be free from obstructions and securely  
installed. If not, battery gases could accumulate and cause an explosion. The  
tube should be routed away from the frame and body to prevent corrosion.  
Avoid skin contact with electrolyte, severe burns could result.  
3. First connect and tighten the red (positive) cable.  
4. Second connect and tighten the black (negative) cable.  
5. Verify that cables are properly routed.  
6. Reinstall battery cover and attach the hold down strap.  
NOTE:  
D
W
h
e
n
y
o
u
r
R
A
N
G
E
R
i
s
p
l
a
c
e
d
i
n
s
t
o
r
a
g
e
f
o
r
t
h
r
e
e
m
o
n
t
h
s
o
r
m
o
r
e
,
t
h
e
b
a
t
t
e
r
y
should be removed, charged to proper level, and stored in a cool dry place.  
D
Before reusing, take the battery to your dealer for testing and recharging.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Schedule  
Careful periodic maintenance will help keep your vehicle in the safest, most reliable  
condition. Inspection, adjustment and lubrication intervals of important compo-  
nents are explained in the following chart:  
Maintenance intervals are based upon average riding conditions and a vehicle  
speed of approximately 10 miles per hour. Vehicles subjected to severe use, such  
as operation in wet or dusty areas, should be inspected and serviced more fre-  
quently. If you are not familiar with safe service and adjustment procedures, have  
a qualified dealer perform these operations.  
Inspect, clean, lubricate, adjust or replace parts as necessary.  
J
CAUTION: Due to the nature of these adjustments, it is recommended that  
service be performed by an authorized Polaris dealer. Do not attempt to perform  
this work unless you are familiar with mechanical repair.  
"
L
More often under severe use, such as dirty or wet conditions  
Emission Control System Service (California)  
NOTE: Inspection may reveal the need for replacement parts. Always use genu-  
ine Polaris parts available from your Polaris dealer.  
Item  
Hours or  
Odometer  
Frequency  
Remarks  
Engine Oil - Level/Change  
(4-Cycle)  
100 hrs/1000 6 months  
miles  
Check Level Daily; Break in Service at  
1 month. Change oil more often in cold  
weather use.  
"
L
Oil Filter  
100 hrs/1000 6 months  
miles  
Replace with oil change  
"
"
L
L
Engine breather filter  
Engine breather hose  
Engine Mounts  
20 hrs  
Monthly  
Inspect–replace annually and as need-  
ed  
100 hrs  
6 months  
Inspect  
L
100 hrs  
25 hrs  
12 months  
3 months  
Inspect  
Engine Cylinder Head and  
Cylinder Base Fasteners  
Inspect (re-torque required at first ser-  
vice only)  
Air Filter - Main Element  
Valve Clearance  
Spark Plug  
Weekly  
100 hrs  
100 hrs  
100 hrs  
Weekly  
Inspect-Replace if necessary  
Inspect/Adjust  
"
J
L
12 months  
12 months  
12 months  
L
Inspect–replace if necessary  
Inspect and adjust as needed  
L
Ignition Timing  
J
L
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Schedule (Cont.)  
Item  
Hours or  
Odometer  
Frequency  
Remarks  
Fuel System  
100 hours  
12 months  
Check for leaks at fuel cap, lines, fuel  
valve, filter, pump and carburetor. Re-  
place lines every two years.  
J
L
J
J
Fuel Filter  
100 hrs  
50 hrs  
12 months  
6 months  
Replace annually  
Carburetor Float Bowl  
Drain bowl periodically and prior to stor-  
age  
Idle Speed  
As Required  
50 hrs  
As Required  
6 months  
Adjust  
L
J
Throttle Cable  
Inspect–adjust, lubricate, replace if nec-  
essary; pre-ride inspection item  
Choke (Enricher) Cable  
Coolant/Level Inspection  
50 hrs  
Daily  
6 months  
Daily  
Inspect–adjust, lubricate, replace if nec-  
essary  
L
Replace engine coolant every two  
years  
Coolant strength/pressure test  
system  
100 hrs  
6 months  
Inspect strength seasonally; pressure  
test system annually  
Radiator  
50 hrs  
12 months  
12 months  
12 months  
As required  
3 months  
6 months  
12 months  
12 months  
Monthly  
Inspect/clean external surface  
Inspect  
Cooling System hoses  
Spark arrestor  
100 hrs  
100 hrs  
As required  
30 hrs  
Clean out  
Recoil housing  
Drain moisture out after driving in water  
Lubricate all fittings, pivots, cables, etc.  
Check monthly  
"
"
"
"
"
General Lubrication  
Front hubs/fluid check (AWD)  
Front hubs/fluid change (AWD)  
Front Gearcase Oil  
Transmission Oil Level  
Shift linkage  
50 hrs  
100 hrs  
100 hrs  
25 hrs  
Check monthly and change annually  
Inspect monthly; change annually  
Inspect, adjust  
50 hrs  
6 months  
24 months  
6 months  
12 months  
6 months  
As required  
J
J
J
J
J
Shift selector box  
Drive belt  
200 hrs  
50 hrs  
Change lubricant every two years  
Inspect–adjust, replace if necessary  
Inspect, clean  
Clutches (drive and driven)  
Steering  
100 hrs  
50 hrs  
Inspect daily, lubricate  
Toe adjustment  
As required  
Periodic inspection, adjust when parts  
are replaced  
"
"
J
Front Suspension  
Rear Suspension  
Front wheel bearings  
Battery  
50 hrs  
6 months  
6 months  
36 months  
monthly  
Inspect–lubricate, tighten fasteners  
Inspect, tighten fasteners  
Replace  
50 hrs  
300 hrs  
20 hrs  
Check Terminals/clean/check fluid level  
Adjust if necessary  
Headlight Aim  
As required  
As required  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Schedule (Cont.)  
Item  
Hours or  
Odometer  
Frequency  
Remarks  
Headlamp Inspection  
Daily  
Daily  
Daily  
Check operation daily; apply Polaris di-  
electric grease to connector when re-  
placed  
Tail lamp inspection  
Daily  
Check operation daily; apply Polaris di-  
electric grease to socket when replaced  
Brake System  
Brake fluid  
Pre-ride  
200 hrs  
Pre-ride  
Pre-ride inspection item  
Change every two years  
Inspect periodically  
J
J
24 months  
Monthly  
Brake pad wear  
10 hrs/100  
miles  
Parking Brake  
Pre-Ride  
Pre-ride  
Pre-ride  
Pre-ride  
Pre-Ride  
Pre-ride  
Pre-ride  
Pre-ride  
Check lever adjustment daily; adjust  
Inspect daily, pre-ride inspection item  
Pre-ride inspection item  
Tires  
Wheels  
Frame nuts, bolts, fasteners  
Pre-ride inspection item  
J
CAUTION: Due to the nature of these adjustments, it is recommended that  
service be performed by an authorized Polaris dealer. Do not attempt to perform  
this work unless you are familiar with mechanical repair.  
"
L
More often under severe use, such as dirty or wet conditions  
Emission Control System Service (California - 4-Cycle)  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
Item  
Lube Rec.  
Method  
Frequency*  
1.Engine Oil  
Polaris Pre-  
mium 4 Syn- See page 37.  
thetic 0W40  
Add to proper level on dipstick.  
Check level dai-  
ly.  
2. Brake Fluid  
DOT 3 Only  
Maintain level between fill lines.  
See page 78.  
As required;  
change every  
two years or 200  
hours  
3. Transmission  
Oil  
Polaris Pre-  
mium Syn-  
thetic chain  
case lube  
Add to FULL level on dipstick.  
See page 66.  
Change annually  
or at 100 hours  
4. Front Gear-  
case Oil  
GL5 80-90  
Fill to bottom thread of filler hole.  
Change annually  
Weight Gear Make certain machine is on level  
Lube  
surface.  
5. Center Half-  
shafts  
Grease+  
Locate Fittings and Grease  
Every 3 months  
or 50 hours  
6. Front Prop  
Shaft U-joints  
Grease+  
Locate Fittings and Grease  
Every 3 months  
or 50 hours  
7. Front Prop-  
shaft Yoke  
Grease+  
Locate fittings and grease – 3  
pumps maximum  
Every 3 months  
or 50 hours  
Premium  
Hub Lube  
Remove set screw in hubs. Ro-  
Annually or at  
8. Demand 6  
Hubs - All  
tate wheels to 4 O’clock position. 100 hrs  
If lubricant is not visible add more.  
Reinstall set screw.  
Wheel Drive  
9. Front Drive  
Axle (U Joint)  
Grease+  
Locate grease fitting and grease  
with grease gun.  
Every 3 months  
or 50 hours  
10. Ball Joint  
Grease**  
Locate fitting on back side of  
struts and grease with grease  
gun.  
Every 3 months  
or 50 hours  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
4. Front Gear Case  
3. Transmission  
Full  
Fill plug  
Operating  
Range  
6. Front Prop Shaft  
(U-Joint)  
7. Propshaft Yoke  
5. Center Halfshaft  
(U Joint)  
9. Axle Cardan  
Front Drive  
(AWD Models)  
8. Demand Hubs  
Upper  
11. Front A-Arm  
Pivot Shaft  
8. 4 O’clock  
position  
10
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
11. Front A Arm  
Grease**∆ Locate fitting on pivot shaft and  
Every 3  
months or 50  
hours  
Pivot Shaft  
grease with grease gun.  
12. Swing Arm  
Bushings  
Grease**  
Locate fittings on swing arm and  
grease with grease gun.  
Monthly or at  
20 hours  
13. Upper Control Grease**∆ Locate fittings and grease  
Semi-annually  
Semi-annually  
Semi-annually  
Arms  
14. Lower Control Grease**∆ Locate fittings and grease  
Arms  
15. Center Wheel Grease**∆ Locate fitting and grease  
Hub Bearing Car-  
rier  
16. Tail Shaft  
Coupler  
Grease**∆ Locate Fitting and grease  
Monthly or at  
20 hours  
17. Center and  
rear angle drives  
GL5 80-90 Fill to bottom thread of filler hole.  
Monthly or at  
20 hours  
weight  
Make certain machine is on a level  
surface.  
gear lube  
* More often under severe use, such as wet or dusty conditions.  
**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as  
Conoco Superlube M or Mobilegrease Special.  
+ Grease every 500 miles, or after submerging in water or before long periods of storage or  
after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of  
these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).  
∆ When suspension action becomes stiff or after washing.  
NOTE: Hours are based on 10 mph average.  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
13. Upper Control  
Arm  
16.  
17.  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
WARNING  
Vehicle operation with insufficient, deteriorated, or contaminated engine  
oil will cause accelerated wear and may result in engine seizure, acci-  
dent, and injury.  
Engine Oil  
In order for the engine to function  
properly, maintain the engine oil at the  
proper level, and change the oil and  
oil filter in accordance with the Period-  
ic Maintenance Schedule. Not only  
do dirt and metal particles collect in  
the oil, but the oil itself loses its lubrica-  
tive quality if used too long.  
1
The transmission cover/dipstick (1) is  
located on the right side of the ma-  
chine inside the chassis.  
2
Transmission Oil  
The transmission lubricant level  
should be checked monthly (or 1000  
miles (1600 km), whichever comes  
first. Transmission oil should be  
changed annually.  
To check the transmission lubricant  
level you must first position the ve-  
hicle on a level surface. Remove the  
right engine access panel as de-  
scribed on page 35. Reach inside the  
engine compartment in the direction  
indicated by the arrow (2). Remove fill  
plug dipstick (3) by pulling upward and  
check the lubricant level. Lubricant  
should be kept at the full mark on the  
dipstick. The correct transmission lu-  
bricant to use is Polaris Premium Syn-  
thetic Gearcase Lubricant (PN  
2871478).  
A
3
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transmission Oil Changing  
Procedure  
1. Locate and remove fill plug/  
dipstick.  
2. Remove transmission drain  
plug located on the bottom  
right hand side and drain the  
oil. Catch and discard used oil  
properly.  
3. Clean and reinstall the drain  
plug.  
4. Add Polaris Premium Syn-  
thetic Gearcase Lubricant  
(PN 2871478) to full mark on  
the fill plug/dipstick.  
perating  
ange  
Full  
5. Check for leaks.  
CAUTION: Be careful not to allow any dirt or foreign materials to enter the trans-  
mission case.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Front Gearcase Lubrication  
Fill plug/Dipstick  
Front Gearcase Lubrication  
The front gearcase fill plug is located on the right side of the front gearcase.  
The front gearcase lubricant level should be checked every six months or 1000  
miles (1600 km), whichever comes first. Front gearcase oil should be changed  
annually. With the RANGER on a level surface, remove fill plug and check the lubri-  
cant level. Lubricant should be kept at the bottom thread of the fill plug hole. The  
correct gearcase lubricant to use is GL5 80-90 Weight Gear Lube.  
Gearcase Oil Changing Procedure  
1. Remove fender panel.  
2. Remove fill plug/dipstick.  
3. Remove gearcase drain plug located on the bottom right hand side and drain  
the oil. Catch and discard used oil properly.  
4. Clean and reinstall the drain plug.  
5. Add GL5 80-90 Weight Gear Lube to the bottom thread of the fill plug hole.  
6. Check for leaks.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
The following items should be checked occasionally for tightness; or if they have  
been loosened for maintenance service.  
Axle and Wheel Nut Torque Specifications  
Front Spindle Nut(s)  
Front Wheel Nuts  
Dealer Performed Service  
15 Ft. Lbs.  
Center and Rear Hub  
Retaining Nut(s)  
120 Ft. Lbs.  
Rear Wheel Nuts  
15 Ft. Lbs.  
Front Wheel Hub Tightening  
Front wheel bearing tightness and spindle nut retention are critical component op-  
erations. Service work must be performed by your authorized Polaris dealer.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Rear Spring Adjustment  
The rear shock absorber springs are  
adjusted by rotating the adjuster in  
the direction required to increase or  
decrease spring tension.  
Rear Spring  
Adjustment  
Cam  
Air Filter Service  
It is recommended that the air filter be  
replaced yearly. When riding in ex-  
tremely dusty conditions replace-  
ment will be required more often.  
1. Open the hood.  
2. Remove the cover. Inspect the  
gasket. It should adhere tightly to  
the cover and seal all the way  
around.  
3. Remove the air filter. Do not attempt to clean the main element.  
4. Install new air filter. NOTE: Apply a small amount of general purpose grease  
to the sealing edges of the filter before installing.  
5. Check air box. If oil or water deposits are found, drain them into a suitable con-  
tainer. NOTE: Service more frequently if vehicle is operated in wet conditions  
or at high throttle openings for extended periods.  
Air Filter  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
CAUTION: Operation of your vehicle without a breather filter can cause engine  
damage.  
Breather Filter and Hoses  
Do not perform this operation immediately after the engine  
has been run. The exhaust system becomes very hot and  
can cause severe burns.  
WARNING  
1. Open hood and locate the  
airbox (1).  
1
2. Follow right hand breather  
line out of the back of the  
airbox and locate filter (2).  
3. Inspect filter for debris. Blow  
through gently in direction of  
arrow on filter to check for  
clogging.  
needed.  
Replace as  
4. Check hoses for cracks,  
deterioration, abrasion, or  
leaks. Replace as needed.  
5. Reinstall filter and clamps  
with arrow pointing toward  
engine.  
2
Radiator and Cooling Fan  
Check and clean the grille, screen and radiator fins for obstruction by insects or  
mud in accordance with the Periodic Maintenance Chart.  
CAUTION: Using high-pressure water, as from a car wash facility, could damage  
the radiator fins and impair the radiator’s effectiveness.  
Do not obstruct or deflect airflow through the radiator by installing unauthorized ac-  
cessories in front of the radiator or behind the cooling fan. Interference with the  
radiator airflow can lead to overheating and consequent engine damage.  
Coolant absorbs excessive heat from the engine and transfers it to the air at the  
radiator. If the coolant level becomes low, the engine overheats and may suffer  
damage. Check the coolant level each day before operating the vehicle, and re-  
plenish coolant if the level is low. Change the coolant in accordance with the Peri-  
odic Maintenance Chart.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Coolant Level Inspection  
NOTE: Check the coolant level  
when the engine is cold (room or  
atmospheric temperature).  
Radiator Cap  
1. Situate the vehicle on level  
ground.  
2. Check the coolant level  
through the coolant level  
gauge on the reserve tank lo-  
cated Behind the left hand en-  
gine compartment panel. The  
coolant level should be be-  
tween the F (Full) and L (Low)  
marks.  
3. If the amount of coolant is not  
within the operating range, un-  
screw the cap from the reserve  
tank. Using a funnel, add cool-  
ant through the filler opening to  
the F (Full) mark. Install the  
cap.  
Coolant Bottle  
NOTE: Polaris recommends the  
use of Polaris Premium 60/40 anti-  
freeze/coolant or a 50/50 mixture  
of high quality aluminum compat-  
ible anti-freeze/coolant and dis-  
tilled water. IMPORTANT: Polaris  
Premium 60/40 is already pre-  
mixed and ready to use. Do not di-  
lute with water. IMPORTANT: Al-  
ways follow the manufacturer’s  
mixing recommendations for the  
freeze protection required in your  
area.  
NOTE: In an emergency you can add water alone to the coolant reserve tank, how-  
ever it must be returned to the correct mixture ratio by the addition of antifreeze con-  
centrate as soon as possible.  
CAUTION: If coolant must be added often, or the reserve tank completely runs dry,  
it is possible there is a leak in the system. Have the cooling system inspected by  
your Polaris RANGER dealer.  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
D
D
D
D
D
Proper electrode gap is .028″/.7mm.  
Spark plug torque is 17 ft. lbs. (2.3 kg/m).  
Use NGK BKR5ES spark plugs.  
Proper electrode gap is .025″ (.06 cm).  
Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs  
(1.52 kg/m) for a new spark plug.  
Spark plug condition is indicative of engine operation. The spark plug firing end  
condition should be read after the engine is warmed up and the vehicle is driven  
at higher speeds. Immediately check the spark plug for correct color.  
1. Normal  
The insulator tip is gray, tan or light brown. There will be few combustion deposits.  
The electrodes are not burned or eroded. This indicates the proper type and heat  
range for the engine and the service.  
NOTE: The tip should not be white. A white insulator tip indicates overheating,  
caused by use of an improper spark plug or incorrect carburetion adjustments.  
2. Wet Fouled  
The insulator tip is black. A damp oil film covers the firing end. There may be a  
carbon layer over the entire nose. Generally, the electrodes are not worn. General  
causes are excessive oil, use of non-recommended injection oil, improper use of  
the choke, or incorrect carburetion adjustments.  
Spark Plug Removal and Replacement  
WARNING: Never attempt to remove a spark plug while the engine is warm.  
The exhaust system or engine could burn you causing severe injury.  
The spark plug is removed by using the special wrench provided in the tool pouch  
under the seat. Reach inside the right hand engine access panel and then back  
for access. Remove the spark plug cap and then the spark plug by rotating coun-  
terclockwise.  
Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. (2.3 kg/m).  
Never deviate from the recommended spark plug as engine damage can occur.  
Cylinder Head/Cylinder Base Fastener Torque  
Have your dealer check the RANGER cylinder head and cylinder base fasteners  
for proper torque at the first service or after 25 hours.  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Arrestor  
The exhaust pipe must be period-  
ically purged of accumulated car-  
bon as follows:  
1. Remove the clean out plugs  
located on the bottom of the  
muffler as shown above.  
2. Place the transmission in  
neutral and start the engine.  
Purge accumulated carbon  
from the system by momen-  
tarily revving the engine sev-  
eral times.  
Clean Out Plug  
3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around  
the clean out plugs while revving the engine several more times.  
4. If particles are still suspected to be in the muffler, back the machine onto an in-  
cline so the rear of the machine is one foot higher than the front. Set the parking  
brake and block the wheels. Make sure the machine is in neutral and repeat  
steps 2 and 3. WARNING: SEE BELOW.  
5. If particles are still suspected to be in the muffler, drive the machine onto the  
incline so the front of the machine is one foot higher than the rear. Set the park-  
ing brake and block the wheels. Make sure the machine is in neutral and repeat  
steps 2 and 3. WARNING: SEE BELOW.  
6. Repeat steps 2 through 5 until no more particles are expelled when the engine  
is revved.  
7. Stop the engine and allow the arrestor to cool.  
8. Reinstall the arrestor plugs.  
WARNING  
D Because exhaust system temperatures can reach 1000°F, do not perform  
this operation immediately after the engine has been run because the ex-  
haust system becomes very hot.  
D
Because of the increased fire hazard, make sure that there are no com-  
bustible materials in the area when purging the spark arrestor.  
D
Wear eye protection.  
D
D
o
n
o
t
s
t
a
n
d
b
e
h
i
n
d
o
r
i
n
f
r
o
n
t
o
f
t
h
e
v
e
h
i
c
l
e
w
h
i
l
e
p
u
r
g
i
n
g
t
h
e
c
a
r
b
o
n
f
r
o
m
the spark arrestor.  
D
N
e
v
e
r
r
u
n
t
h
e
e
n
g
i
n
e
i
n
a
n
e
n
c
l
o
s
e
d
a
r
e
a
.
T
h
e
e
x
h
a
u
s
t
c
o
n
t
a
i
n
s
p
o
i
s
o
n
-
ous carbon monoxide gas.  
D
Do not go under the machine while it is inclined.  
Failure to heed these warnings could result in serious personal injury or death.  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Tool Kit  
To help you perform routine maintenance, a tool kit is provided in the storage  
compartment under the seat. Items included in the kit are:  
D
D
D
D
D
screwdriver  
open end wrench (8-10 mm)  
open end wrench (12-14 mm)  
tire pressure gauge  
spark plug wrench and handle  
NOTE: Other tools are also necessary to perform maintenance work. They are  
called out later in this manual.  
PVT System  
WARNING  
The PVT system rotates at high speeds, creating large amounts of force  
on clutch components. Extensive engineering and testing has been con-  
ducted to insure the safety of this product. However, as the owner you  
have the following responsibilities to make sure this system remains safe:  
D Do not modify any component of the PVT system. Doing so may reduce  
its strength so that a failure may occur at high speeds. This system has  
been precision balanced. Any modification will cause the system to be  
out of balance, creating vibration and additional loads on components.  
D
Routine maintenance is the responsibility of the owner. Always follow  
recommended maintenance procedures. See your dealer!  
D
D
This PVT system is intended for use on Polaris products only.  
The PVT housing must be securely in place during operation.  
Failure to comply with this warning can result in severe injury or death.  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Throttle Pedal  
If the throttle pedal (1) has exces-  
sive play due to cable stretch or  
cable misadjustment, it will cause a  
delay in throttle response, especial-  
ly at low engine speed. Also, the  
throttle may not open fully. If the  
throttle pedal has no play, the  
throttle may be hard to control, and  
the idle speed may be erratic.  
Check the throttle pedal play period-  
ically in accordance with the Period-  
ic Maintenance Chart and adjust the  
play if necessary.  
1
Throttle Freeplay Inspection  
1. Apply the parking brake.  
2. Put the gear shift lever in the N  
(Neutral) position.  
3. Start the engine, and warm it up  
thoroughly.  
4. Measure the distance the  
throttle pedal moves before the  
engine begins to pick up speed.  
Free play should be 1/16 - 1/8  
inches.  
Adjustment  
If adjustment is necessary, adjust  
the throttle freeplay using the follow-  
ing procedure:  
1. Loosen jam nut on cable where  
it connects to the throttle brack-  
et.  
2. Adjust cable to specified free-  
play.  
3. Tighten jam nuts securely.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor  
The idle speed adjustment should be performed in accordance with the Periodic  
Maintenance Chart or whenever the idle speed is changed. The following proce-  
dure covers the idle speed adjustment:  
Carburetor/Engine Idle RPM Adjustment  
Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not  
satisfactory, and all other conditions are favorable, the carburetor can be adjusted  
as follows:  
1. Apply the parking brake.  
2. Put the gear shift lever in the N  
(Neutral) position.  
3. Warm up the engine by running  
the vehicle approximately five  
minutes.  
4. Remove the right hand engine  
compartment access panel and  
locate the idle screw.  
5. Place the transmission in gear  
with the parking brake applied.  
6. Adjust the carburetor idle screw  
Idle Screw  
in or out until the desired idle  
RPM is reached . Turning the  
screw in (clockwise) will raise  
RPM. Turning the screw out  
(counterclockwise) will lower  
RPM.  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Front and Rear Brakes  
The front and brakes are hydraulic  
disc type brakes activated by the  
brake pedal.  
The following checks are recom-  
mended to keep the brake system in  
good operating condition. How often  
they need checking depends upon  
the type of driving that has been done.  
1
D
Inspect the level of the brake  
fluid before each ride. Change  
the brake fluid according to the  
Periodic Maintenance Chart. The  
brake fluid should also be  
changed if it becomes contami-  
nated with dirt or water.  
D
D
To check the fluid level, the vehicle must be on level ground. Inspect the  
brake fluid by looking at the remote reservoir (1) under the hood. The level  
should be between the upper (MAX) and lower (MIN) level lines.  
If the fluid level is lower than the lower level line, add brake fluid to the upper  
(MAX) line. Apply the brake forcefully for a few seconds and check for fluid  
leakage around the fittings.  
WARNING: Change the fluid in the brake system completely if the fluid level is low  
but the type and brand of the fluid already in the reservoir are unknown.  
WARNING: Once a bottle of brake fluid is opened, use what is necessary and dis-  
card the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygro-  
scopic, meaning it rapidly absorbs moisture from the air. This causes the boiling  
temperature of the brake fluid to drop, which can lead to early brake fade and the  
possibility of serious injury.  
D
Check brake system for fluid leaks.  
D
Check brake for excessive travel or  
spongy feel.  
WARNING: If the brake pedal has a soft  
“spongy” feeling” when it is applied, there  
could be air in the brake lines or the brake may  
be defective. Do not operate the vehicle under  
these conditions. Have the brake system ser-  
viced by an authorized Polaris dealer immedi-  
ately.  
D
D
D
Check friction pads for wear, damage  
and looseness.  
3/64″ (.1 cm)  
Check security and surface condition of  
the disc.  
Pads should be changed when worn to  
3/64″ (.1 cm), or about the thickness of a  
dime.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Rear Brake  
The rear brake is a hydraulic disc  
type brake which is activated by the  
same pedal which activates the front  
brake system. The rear brake sys-  
tem is self adjusting and requires no  
maintenance other than periodic  
checks of the pads for wear.  
Wear Line  
D
Pads should be changed when  
worn to 3/64″ (.1 cm) which is  
about the thickness of a dime.  
3/64″ (.1 cm)  
D
Inspect the brake disc spline and pad wear surface for excessive wear.  
WARNING: Due to the nature of this type of vehicle and where it is operated,  
headlight and taillight lenses may become dirty. Frequent washing is necessary  
to maintain lighting quality. Poor lighting while riding can result in severe injury or  
death.  
CAUTION: Do not service while lights are hot. Serious burns may result.  
Brake Light Switch  
When the brake pedal is depressed, the brake light goes on. Check the brake light  
switch before each ride.  
To inspect the brake light, first turn the ignition switch to the ON position.  
Depress the brake pedal. The brake light should go on after about 10mm (0.4 in.)  
of pedal travel.  
If the light does not go on, check the bulb.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Parking Brake Lever  
The parking brake helps hold the  
vehicle from rolling while parked.  
Make sure the parking brake lever  
is functioning properly before each  
ride.  
2
Inspection:  
D
Pull the parking brake lever  
up and to the rear.  
1
D
After 8 to 12 clicks of lever  
travel, the vehicle should not  
roll while parked.  
D
If the vehicle moves, adjust-  
ment is necessary  
Adjustment:  
D
Loosen the locknut (1) (lower nut) on the lower end of the parking brake  
lever cable and turn the nut next to the locknut (2) until the brake lever will  
only move 8 - 12 clicks upward.  
D
Tighten the locknut securely  
NOTE: Be sure to hold the cable end with a wrench to prevent the cable from twist-  
ing.  
Steering Wheel  
Check the steering wheel for specified free play and smooth operation in accor-  
dance with the periodic maintenance Chart.  
Inspection:  
D
D
D
D
Park the vehicle on level ground.  
Lightly turn the steering wheel left and right.  
There should be 0.8 - 1.0 in (20 - 25 mm) of free play.  
If there is excessive free play or strange noises, or the steering feels rough  
or “catchy,” have the steering system checked by an authorized Polaris deal-  
er.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Wheel Removal Procedure  
1. Stop the engine, place the transmission in gear and lock the parking 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 remove the wheel.  
Wheel Installation  
1. With the transmission in gear and the parking brake locked, place the wheel  
in the correct position on the wheel hub. Be sure the valve stem is toward the  
outside and rotation arrows on the tire point toward forward rotation.  
2. Attach the wheel nuts and finger  
tighten them.  
3. Lower the vehicle to the ground.  
4. Securely tighten the wheel nuts  
according to the chart found on  
page 69:  
CAUTION: If wheels are improperly  
installed it could affect vehicle han-  
dling and tire wear.  
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
WARNING  
Operating your vehicle with worn tires will increase the possibility of the  
vehicle skidding easily with possible loss of control.  
Worn tires can cause an accident.  
Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.  
Tire Inspection  
CAUTION: Maintain proper tire pressure according to charts below. Improper tire  
inflation may affect vehicle maneuverability.  
When replacing a tire always use original equipment size and type.  
CAUTION: The use of non-standard size or type tires may affect vehicle handling.  
Tire Tread Depth  
Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. Please refer  
to your Owner’s Manual Supplement for tire specifications.  
m  
1/8  
I
Tire Specifications  
RANGER 6x6  
Front - 25 x 10.00 -12  
Inflation Pressure - Min 5 - Max 12  
Center - 25 x 11.00 - 10  
Inflation Pressure - Min 5 - Max10  
Rear - 25 x 11.00 - 10  
Inflation Pressure - Min 5 - Max 10  
Cargo Box Load Capacity  
1000 lbs. ( 454 kg)  
Gross Vehicle Weight 3020 lbs.  
(1327 kg) including vehicle, driver, passenger and cargo. Vehicle weighs  
1520 lbs. ( 690 kg).  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Seat Belts  
Make certain each seat belt functions properly before each ride. Push the latch  
plate into the buckle until it clicks. The latch plate must slide smoothly into the  
buckle. The click sound shows it is securely latched. Push the red button in the  
middle of the buckle to make sure it releases freely. Also check the belt webbing  
for wear, cuts or damage. If any irregularities are found, have the seat belt system  
checked or replaced by an authorized Polaris dealer  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Headlight Beam  
The headlight beam can be adjusted up and down.  
1. Place the vehicle on a level surface with the headlight approximately 25’ (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. Start the engine and turn the headlight switch to high beam.  
4. Observe headlight aim. The most intense part of the headlight beam should  
be aimed 2″ (5.1 cm) below the mark placed on the wall in step 2. NOTE: Rider  
weight must be included on the seat.  
5. Loosen pivot bolts and adjust beam to desired position.  
6. Tighten nut and bolt. Torque to 60 in. lbs.  
Indicator Lamp Replacement  
1. Unplug light from harness, depress lock-  
ing tabs and remove from pod.  
2. Install new light and reassemble pod.  
Depress locking  
tabs to remove.  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
Always exercise extreme caution whenever handling gasoline.  
D
D
A
l
w
a
y
s
r
e
f
u
e
l
w
i
t
h
t
h
e
e
n
g
i
n
e
s
t
o
p
p
e
d
a
n
d
o
u
t
d
o
o
r
s
o
r
i
n
a
w
e
l
l
v
e
n
t
i
-
lated area.  
D
D
o
n
o
t
s
m
o
k
e
o
r
a
l
l
o
w
o
p
e
n
f
l
a
m
e
s
o
r
s
p
a
r
k
s
i
n
o
r
n
e
a
r
t
h
e
a
r
e
a
w
h
e
r
e
refueling is performed or where gasoline is stored.  
D
Do not over fill the tank.  
D
I
f
y
o
u
s
h
o
u
l
d
g
e
t
g
a
s
o
l
i
n
e
o
n
y
o
u
r
s
k
i
n
o
r
c
l
o
t
h
i
n
g
,
i
m
m
e
d
i
a
t
e
l
y
w
a
s
h
it off with soap and water and change clothing.  
D Never start the engine or let it run in an enclosed area. Gasoline pow-  
ered engine exhaust fumes are poisonous and can cause loss of con-  
sciousness and death in a short time.  
D
Shut off fuel valve whenever the vehicle is stored or parked.  
WARNING  
The engine exhaust from this  
product contains chemicals  
known to cause cancer, birth de-  
fects or other reproductive harm.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning Your RANGER  
Keeping your vehicle clean will not only improve its appearance but it can also ex-  
tend the life of various components. With a few precautions, your vehicle can be  
cleaned much like an automobile.  
Washing  
If a high pressure type car wash system is used, extreme care must be taken to  
avoid water damage to the wheel bearings, transmission seals, body panels,  
brakes, headlights and warning labels. Many expensive repair bills can result from  
using high pressure detergent systems.  
NOTE: If a high pressure car wash is used, grease all zerk fittings immediately af-  
ter washing. Also run the vehicle to evaporate any water that might have entered  
the engine or exhaust system.  
The best and safest way to clean your vehicle is with a garden hose and a pail of  
mild soap and water. Use a professional type washing mitten, cleaning the upper  
body first and the lower parts last. Rinse with water frequently and dry with a cham-  
ois to prevent water spots. NOTE: If warning labels are damaged, contact your  
a Polaris dealer for free replacement.  
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Storage  
If your vehicle is to be placed in extended  
or off season storage, the following steps  
should be taken to preserve its condition.  
1. Perform all necessary repairs and thor-  
oughly clean the vehicle.  
2. Turn the fuel valve to “off” and drain the  
carburetor.  
Drain tube  
attached  
here  
3. Remove the spark plug and pour  
approximately one ounce of Pre-  
mium 4 oil into the cylinder. Oper-  
ate the starter for a few seconds  
and reinstall the spark plug.  
Drain Screw  
4. Remove the battery. Store it in a cool, dry place out of the sun.  
5. Lubricate suspension pivot points, lower steering post and rear axle fittings.  
6. Drain the recoil housing.  
7. Block the vehicle so all tires are suspended off the ground.  
8. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil  
on rubber parts or in the brakes.  
9. Lubricate all cables.  
10. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture  
or small animals from entering.  
11. Cover the vehicle with a canvas cover. Do not use plastic or coated materials  
since they do not allow ventilation of the vehicle.  
Removal from Storage:  
1. Check the battery electrolyte level, charge the battery if necessary, and install  
it in the vehicle. Take care the battery vent hose is not pinched and routed prop-  
erly.  
2. Make sure the spark plug is tight.  
3. Fill the fuel tank with fuel.  
4. Check all the points listed in the Daily Safety Checks section.  
5. Lubricate per periodic maintenance chart.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
WARNING  
Do not run the engine in a closed area. Exhaust gases contain carbon  
monoxide; a colorless, odorless, poisonous gas. Breathing exhaust  
gas leads to carbon monoxide poisoning, asphyxiation and death.  
Bolt and Nut Tightening  
Tightness of the bolts, nuts and other fasteners should be checked by an autho-  
rized Polaris dealer in accordance with the Periodic Maintenance Chart.  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Procedures  
The following information is provided to help you identify probable causes for ques-  
tions you may have about the operation of your vehicle. See your Polaris dealer  
with any additional questions you may have.  
ENGINE CRANKS BUT FAILS TO START  
No Fuel  
Water in Fuel  
Drain System  
Spark Plug  
No Spark to  
Spark Plug  
Fuel Valve Off  
Clogged Fuel  
Valve  
Contact Your  
Dealer  
ENGINE STOPS OR LOSES POWER  
Overuse of  
Choke  
Spark Plug  
Fouled  
Engine  
Overheated  
No Fuel  
Fuel Vent Line  
Kinked or  
Air Filter  
Clogged  
Clean Radiator  
screen  
Plugged  
Contact Your  
Dealer  
Water in Fuel  
Clean Engine  
Exterior  
Fuel Pump  
Faulty  
Contact Your  
Dealer  
Contact Your  
Dealer  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
Gross Vehicle Weight  
Fuel Capacity  
3020 lbs.  
9.5 Gallons  
Towing Capacity  
1500 lbs.  
C
A
Maximum Cargo Box Load  
1000 lbs.  
P
A
C
I
T
I
Overall Length  
Overall Width  
Overall Height  
Wheelbase  
113 in.  
58 in. (Tires) 60″ (Cargo Box)  
75 in.  
81 in.  
E
S
Ground Clearance  
Dry Weight  
8.5 in.  
1520 lbs.  
Cargo Box (L x W x H)  
Minimum Turning Radius  
Engine Oil Capacity  
Coolant Capacity  
Type  
40 x 59.75 x 9  
168 in.  
2 Quarts  
2.25 Quarts  
4 Cycle, Single Cylinder  
498  
Displacement  
Bore x Stroke  
Pilot Jet  
90 x 75  
42.5  
Main Jet  
125  
Needle Jet  
Q-6  
Jet Needle  
5D78-3  
E
N
G
I
N
E
Air Screw  
1.25 Turns  
250 W  
Alternator Output  
Compression Ratio  
Starting System  
Carburetor  
10.2:1 Full Stroke  
Electric Start w/Recoil Backup  
1 - BST 34 (CV Type)  
CDI  
Ignition System  
Ignition Timing  
Spark Plug  
30° @ 3500 1.5  
NGK BKR5E  
Dry Sump  
0W/40  
Lubrication System  
Engine Oil  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
Driving System Type  
Shift Type  
PVT  
D
R
I
V
E
Single Lever/Center Console  
Gear Reduction - Low  
Gear Reduction - Reverse  
Gear Reduction - High  
Drive Ratio - Front:  
Drive Ratio - Final  
Drive Ratio - Center  
24.16:1  
18.67:1  
11.97:1  
2:1  
T
R
A
I
3.5:1  
1:3.5  
N
Front Final Gear Case Oil Capacity 32 ounces  
T
I
R
E
S
Tire Size - Front  
Tire Size - Rear  
Tire Size - Center  
Type  
25 x 10 - 12 (12 psi MAX)  
25 x 11 - 10 (10 psi MAX)  
25 x 11 - 10 (10 psi MAX)  
Foot pedal activated hydraulic front  
and rear. Mechanical Parking  
Brake  
B
R
A
K
E
S
Front  
Hydraulic disc, Floating caliper  
Rear (Center Axle)  
Parking Brake  
Hydraulic Disc, floating Caliper  
Hand Lever  
Mechanical to center Axle  
L
I
G
H
T
S
Hood Headlight (watts)  
Taillights (watts)  
4 x 35W  
2 x 8.26W  
26.9  
Brake Light (watts)  
Indicator Light (watts)  
1
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
LIMITED WARRANTY  
Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota  
55441-5078, gives a SIX MONTH LIMITED WARRANTY on all components of the  
Polaris RANGER against defects in material or workmanship. This warranty cov-  
ers the parts and labor charges for repair or replacement of defective parts which  
are covered by this warranty. This warranty begins on the date of purchase. This  
warranty is transferrable to another consumer during the warranty period through a  
Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.  
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 war-  
ranty entitlement. If you have not signed the original registration and received the  
“customer copy”, please contact your dealer immediately. NO WARRANTY COV-  
ERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH  
POLARIS.  
Initial dealer preparation and set-up of your vehicle is very important in ensuring  
trouble-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, nor-  
mal wear and tear, abuse or improper handling. This warranty also does not cover  
any vehicle that has been altered structurally, neglected, improperly maintained,  
used for racing, 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 uphol-  
stery 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 de-  
fective 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 DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT  
OR OTHERWISE. Some states do not permit the exclusion or limitation of inciden-  
tal or consequential damages or implied warranties, so the above limitations or ex-  
clusions may not apply to you if inconsistent with controlling state law.  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED  
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR  
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WAR-  
RANTY PERIOD. POLARIS FURTHER 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 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 War-  
ranty Registration 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 Polar-  
is.  
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.  
Engine Oil  
1. Always use Polaris engine oil.  
2. Never substitute or mix oil brands as serious engine damage and voiding of war-  
ranty can result.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 70  
All Wheel Drive . . . . . . . . . . . . . . . . . . . 31  
Backing Up . . . . . . . . . . . . . . . . . . . . . . 54  
Battery Installation . . . . . . . . . . . . . . . . 58  
Battery Maintenance . . . . . . . . . . . . . . 57  
Battery Removal . . . . . . . . . . . . . . . . . . 58  
Brake, Front . . . . . . . . . . . . . . . . . . . . . 78  
Brake, Rear . . . . . . . . . . . . . . . . . . . . . . 79  
Break In Period . . . . . . . . . . . . . . . . . . . 44  
Carburetor Adjustment . . . . . . . . . . . . . 77  
Carrying Loads . . . . . . . . . . . . . . . . . . . 45  
Cleaning Your RANGER . . . . . . . . . . . 86  
Control And Parts Functions . . . . . . 31-43  
Control Parts And Functions . . . . . . 27-30  
Coolant Level . . . . . . . . . . . . . . . . . . . . 34  
Coolant Level Inspection . . . . . . . . . . . 35  
Crossing Streams . . . . . . . . . . . . . . . . . 52  
Cylinder Head Torque. . . . . . . . . . . . . . 73  
Daily Pre-ride Inspection . . . . . . . . . . . . 9  
Demand 6 Drive . . . . . . . . . . . . . . . . . . 31  
Disengaging Wheel Hubs . . . . . . . . . . 33  
Dumping Cargo Bed . . . . . . . . . . . . . 45-55  
Engine Cooling System . . . . . . . . . . 34-36  
Engine Idle Rpm Adjustment . . . . . . . . 77  
Filter Change . . . . . . . . . . . . . . . . . . . 38-39  
Front Gearcase Lubrication . . . . . . . . . 68  
Front Wheel Hub Tightening . . . . . . . . 69  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . 39  
Fuel System . . . . . . . . . . . . . . . . . . . . . 24  
Gearcase Oil Changing Procedure . . . 68  
Indicator Lamp Replacement . . . . . . . . 84  
Load Distribution . . . . . . . . . . . . . . . . 46-47  
Lubrication Recommendations . . . . 62-65  
Maintenance . . . . . . . . . . . . . . . . . . . 59-88  
Maintenance Schedule . . . . . . . . . . . 60-61  
Noise Control System . . . . . . . . . . . . . 56  
Oil Change . . . . . . . . . . . . . . . . . . . . 38-39  
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . 39  
Oil System . . . . . . . . . . . . . . . . . 24 and 37  
Operating Safety . . . . . . . . . . . . . . . . 46-55  
Operation Warnings . . . . . . . . . . . . . 10-19  
Parking On An Incline . . . . . . . . . . . . . 54  
Premium 4 Synthetic Lubricant . . . . . . 37  
PVT System . . . . . . . . . . . . . . . 33 and 75  
Rear Spring Adjustment . . . . . . . . . . . . 70  
Recoil Starter . . . . . . . . . . . . . . . . . . . . 43  
Riding On Slippery Surfaces . . . . . . . . 48  
Spark Arrestor . . . . . . . . . . . . . . . . . . . . 74  
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . 73  
Starting A Cold Engine . . . . . . . . . . . . . 40  
Starting A Warm Engine . . . . . . . . . . . . 42  
Starting The Engine . . . . . . . . . . . . . 40-42  
Tire Inspection . . . . . . . . . . . . . . . . . . . . 82  
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 75  
Torque Specifications . . . . . . . . . . . . . . 69  
Towing Capacities . . . . . . . . . . . . . . . . . 45  
Trail Obstacles . . . . . . . . . . . . . . . . . . . 53  
Transmission Gear Selector  
Operation . . . . . . . . . . . . . . . . . . . 32  
Transmission Oil Changing  
Procedure . . . . . . . . . . . . . . . . . . . 67  
Troubleshooting . . . . . . . . . . . . . . . . . . 89  
Understanding Warnings . . . . . . . . . . . . 1  
Vehicle Identification Numbers . . . . . . 20  
Warranty . . . . . . . . . . . . . . . . . . . . . . 92-93  
Wheel Installation . . . . . . . . . . . . . . . . . 81  
Wheel Removal . . . . . . . . . . . . . . . . . . . 81  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Philips Camcorder CAM110 User Manual
Philips Electric Shaver 6853XL User Manual
Philips Speaker SBC BA130 User Manual
Philips TV VCR Combo 14PV101 User Manual
Pioneer DVD Player DV 667A K User Manual
Pioneer Stereo Receiver VSX 917 S User Manual
Polk Audio Speaker System LC80fx User Manual
Powermate Portable Generator PM0525303s User Manual
ProForm Home Gym PFEX34310 User Manual
Pro Tech Network Card PMC01 User Manual