Polaris Offroad Vehicle 6x6 User Manual

PMS 419

RANGER

800 EFI

RANGER

800 EPS

RANGER CREW® 800 EFI

RANGER 6X6

Owner's Manual

for Maintenance and Safety

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WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

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WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of

POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new

product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles

We believe POLARIS sets a standard of excellence for all utility and recreational vehicles

manufactured in the world today. Many years of experience have gone into the engineering,

design, and development of your POLARIS vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and

recommendations in this owner’s manual. Your manual contains instructions for minor

maintenance, but information about major repairs is outlined in the POLARIS Service

Manual and should be performed only by a factory certified Master Service Dealer® (MSD)

technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be

sure to return to your dealership for all of your service needs during, and after, the warranty

period.

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POLARIS®, RANGER® and RANGER CREW® are registered trademarks of POLARIS Industries Inc.

product information at the time of publication. Due to constant improvements in the design and quality of

production components, some minor discrepancies may result between the actual vehicle and the information

presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.

No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or

procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the

original instructions.

Printed in U.S.A.

2014 RANGER 800 EFI / RANGER 800 EPS / RANGER 6X6 / RANGER CREW 800 Owner’s Manual

P/N 9924689

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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INTRODUCTION

The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations

concerning the operation of this vehicle in your area.

The following signal words and symbols appear throughout this manual and on your vehicle.

Your safety is involved when these words and symbols are used. Become familiar with their

meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate

injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

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INTRODUCTION

WARNING

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

Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently

than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur

quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to

take proper precautions.

• Read this owner’s manual and review the safety DVD that came with your vehicle. A free extra copy

of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety

warnings, precautions and operating procedures before operating the vehicle. Keep this manual with

the vehicle.

• Review the safety DVD and take the free online Recreational Off-Highway Vehicle Association

(ROHVA) training course at www.rohva.org.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s

license to operate this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit

with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if

driving) or on a passenger hand hold.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all product

labels.

• Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other

body parts inside the vehicle at all times.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle

boots.

• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce

operator reaction time.

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INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided.

Remove the spare key and store it in a safe place. An ignition key can be duplicated only by

ordering a POLARIS key blank (using your key number) and mating it with one of your

existing keys. The ignition switch must be replaced if all keys are lost.

Engine Serial Number

VIN (4X4, 6X6)

VIN (CREW)

####

Key

Number

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________

Key Number: ________________________________________________________________________________

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INTRODUCTION

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery

is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

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SAFETY

Safe Riding Gear

The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,

long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance

of injury.

Long

Sleeves

Eye Protection

Long Pants

Gloves

Over-the-Ankle Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle,

always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT)

label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05

label. The ECE mark consists of a circle surrounding the letter E,

followed by the distinguishing number of the country which has granted

approval. The approval number and serial number will also be displayed

on the label.

051039

0006.31

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SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this

POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face

shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE)

bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept

clean.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots

Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle

with bare feet or sandals.

Clothing

Wear long sleeves and long pants to protect arms and legs.

Rider Comfort

Under certain operating conditions, heat generated by the engine and exhaust system can

elevate temperatures in the driver and passenger cab area. The condition occurs most

frequently when a vehicle is being operated in high ambient temperatures at low speeds and/

or high load conditions for an extended period of time. The use of certain windshield, roof

and/or cab systems may contribute to this condition by restricting airflow. Any discomfort

due to heat buildup in this area can be minimized by wearing proper riding apparel and by

varying speeds to increase airflow.

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SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the

instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual

differ from the labels on your vehicle, always read and follow the instructions of the labels

on the vehicle.

If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a

replacement. Replacement safety labels are provided by POLARIS at no charge. The part

number is printed on the label.

Proper Use Warning

Seat Belt/Drive Responsibly

Warning

Proper Use Warning (4X4, 6X6)

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions

with cars and trucks can occur.

• Do not exceed seating capacity: 3 occupants.

7179979

Proper Use Warning (CREW)

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions

with cars and trucks can occur.

• Do not exceed seating capacity: 6 occupants.

7179981

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SAFETY

Safety Labels and Locations

Seat Belt/Drive Responsibly Warning

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belts.

• Wear an approved helmet and protective gear.

• ALWAYS use vehicle cab nets and/or doors.

• Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering

wheel or hand holds. Stay completely inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing,

and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even from a stop.

• Plan for hills, rough terrain, ruts and other changes in traction and

terrain. Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk of injury:

• Keep a firm grip on the steering wheel or hand holds and brace

Rollovers have caused

yourself.

severe injuries and death,

even on flat, open areas.

• Do not put any part of your body outside of the vehicle for any

reason.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org).

7179984

Payload Warning

WARNING

Payload Warning

RANGER

Never Exceed

25 mph (40 kph)

If Total Payload

Exceeds

4x4 Gas

630 lbs. (285 kg)

1230 lbs. (558 kg)

1080 lbs. (490 kg)

CA 4x4 Gas 40 mph (65 kph)

Crew Gas

4x4 Diesel

35 mph (56 kph)

25 mph (40 kph)

7180172

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SAFETY

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

Storage Box Load 250 lbs. (113 kg)

WARNING

• Never carry passengers in cargo box.

• Passengers can be thrown off. This can cause serious

injury or death.

IMPROPER TIRE PRESSURE OR OVERLOADING CAN

CAUSE LOSS OF CONTROL RESULTING IN SERIOUS

INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when

carrying cargo.

• Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be

centered and carried as low as possible in box.

• For stability on rough or hilly terrain, reduce speed and

cargo.

RANGER

4 x 4

6 x 6

Crew

CA 4 x 4

MAXIMUM CARGO BOX

LOAD

1000 lbs.

(454 kg)

1250 lbs.

(567 kg)

1000 lbs.

(454 kg)

600 lbs.

(272 kg)

TIRE PRESSURE IN PSI

(KPa)

FRONT 10 (69) FRONT 10 (69) FRONT 12 (83) FRONT 10 (69)

REAR 12 (83) CENTER 12 (83) REAR 14 (97)

REAR 12 (83)

MAXIMUM WEIGHT

CAPACITY INCLUDES

WEIGHT OF OPERATOR,

PASSENGER, CARGO

AND ACCESSORIES

1500 lbs.

(682 kg)

2000 lbs.

(907 kg)

1750 lbs.

(795 kg)

1100 lbs.

(499 kg)

Read Operation and Maintenance Manual for more detailed loading information.

7180170

Clutch Cover Warning

WARNING

NO STEP

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with

guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive

engine RPM which can result in serious injury or death.

7172563

Shift Caution

CAUTION

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

7172674

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are

outlined in further detail within your owner's manual.

• Read this entire manual and all labels carefully. Follow the operating procedures

described.

• Never allow anyone under the age of 16 to operate this vehicle and never allow anyone

without a valid driver's license to operate this vehicle.

• Do not carry a passenger until you have at least two hours of driving experience with this

vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be

able to sit with backs against the seat, both feet flat on the floor and both hands on the

steering wheel (if driving) or on a passenger hand hold.

• The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,

long pants, over-the-ankle boots and seat belt at all times.

• Always use the cab nets (or doors) while riding in this vehicle.

• Always keep hands and feet inside the vehicle at all times.

• Always keep both hands on the steering wheel and both feet on the floorboards of the

vehicle during operation.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all

product labels.

• To reduce rollover risk, be especially careful when encountering obstacles and slopes and

when braking on hills or during turns.

• This vehicle is for off-road use only. Never operate on public roads (unless marked for off-

road use). Always avoid paved surfaces.

• Never consume alcohol or drugs before or while operating this vehicle.

• Never operate at excessive speeds. Always travel at a speed proper for the terrain,

visibility and operating conditions, and your experience.

• Never attempt jumps or other stunts.

• Always inspect the vehicle before each use to make sure it's in safe operating condition.

Always follow the inspection procedures described in this manual.

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SAFETY

Operator Safety

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert

to changing terrain.

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

• Always follow proper procedures for turning. Practice turning at slow speeds before

attempting to turn at faster speeds. Never turn at excessive speeds.

• Always have this vehicle checked by an authorized POLARIS dealer if it has been

involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice

on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in this manual. See page

41. Check the terrain carefully before attempting to climb a hill. Never climb hills with

excessively slippery or loose surfaces. Never apply throttle suddenly. Never make sudden

gear changes. Never go over the top of a hill at high speed.

• Always follow the proper procedures outlined in this manual for traveling downhill and

for braking on hills. See page 41. Check the terrain carefully before descending a hill.

Never travel downhill at high speed. Avoid going downhill at an angle, which would cause

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

• Always check for obstacles before operating in a new area. Never attempt to operate over

large obstacles such as large rocks or fallen trees. Always follow the proper procedures

outlined in this manual when operating over obstacles. See page 40.

• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly

and exercise caution to reduce the chance of skidding or sliding out of control.

• Never operate your vehicle in fast-flowing water or in water deeper than that specified in

this manual. See page 42. 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.

• Always be sure there are no obstacles or people behind your vehicle when operating in

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

in reverse.

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SAFETY

Operator Safety

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

proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of non-POLARIS-

approved accessories.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly

distributed and securely attached. Reduce speed and follow the instructions in this manual

for hauling cargo or pulling a trailer. Allow a greater distance for braking.

• Always engage the park brake before getting out of the vehicle. See page 25.

• Always apply the brakes before engaging or releasing the park brake.

• Always stop the engine before refueling. Remove flammable material containers from the

box before filling them with fuel. Make sure the refueling area is well ventilated and free

of any source of flame or sparks. Gasoline is extremely flammable. See page 18 for fuel

safety warnings.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use

by someone under the age of 16 or without a driver’s license and proper training, or

accidental starting.

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

Equipment Modifications

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose

of increasing speed or power. Any modifications or installation of non-POLARIS-approved

accessories could create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved

equipment and/or modifications have been added to the vehicle that increase speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires,

sprayers, or large racks, may change the handling characteristics of the vehicle. Use only

POLARIS-approved accessories, and familiarize yourself with their function and effect on

the vehicle.

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SAFETY

Operator Safety

WARNING

Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover,

which may result in serious injury or death. Heed all safety warnings outlined in this section of the

owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. NEVER operate this

vehicle if you are under age 16 and NEVER operate without a valid

driver’s license.

Never operate with a passenger under the age of 12. All riders must

be able to sit with backs against the seat, both feet flat on the floor

and both hands on the steering wheel (if driving) or on a passenger

hand hold.

Operating Without Instruction

Operating this vehicle without proper instruction increases the risk of an

accident. The operator must understand how to operate the vehicle

properly in different situations and on different types of terrain.

All operators must read and understand the Owner's Manual and all

warning and instruction labels before operating the vehicle.

All operators should review the safety DVD provided with this vehicle

and take a ROHVA training course (www.rohva.org).

Using Alcohol or Drugs

Operating the vehicle after consuming alcohol or drugs could adversely

affect operator judgment, reaction time, balance and perception.

Never drink alcohol or use drugs or medications before or while

operating this vehicle.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of

serious injury in the event of rollover, loss of control, other accident or

sudden stop. Seat belts may reduce the severity of injury in these

circumstances.

All riders must wear seat belts at all times.

Protective Apparel

Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of

a serious injuries in the event of an accident.

Operator and all passengers must always wear an approved helmet that fits properly and eye

protection (goggles or face shield).

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SAFETY

Operator Safety

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious

injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in

this vehicle.

Always keep hands and feet inside the vehicle at all times.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases

the risk of an accident. Always perform the pre-ride inspection before each use of your RANGER to

make sure it's in safe operating condition. See page 35.

Always follow all inspection and maintenance procedures and schedules described in this owner's

manual. See page 59.

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of

others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the

instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the

specifications section of this manual and on a label on the vehicle. When more passenger weight is

added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications section of this manual and on a label

on the vehicle.

Always follow these guidelines:

Under ANY of these conditions:

Passenger and/or cargo exceeds half the maximum weight capacity

Operating in rough terrain

Do ALL of these steps:

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when

operating.

Operating over obstacles

Climbing an incline

Towing

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SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

• Always use an approved gasoline container to store fuel and remove the container from the vehicle

before filling to avoid fuel ignition due to electrical static discharge.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or

where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change

clothing.

Exposure to Exhaust

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

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

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other

reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a

qualified service dealer inspect the entire machine for possible damage, including (but not limited to)

seat belts, rollover protection devices, brakes, throttle and steering systems.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always

operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills

and experience and your passengers’ skills and experience.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle

on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the

handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid

operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid

sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another

vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads

(unless designated for off-highway use). In some areas it's unlawful to operate this vehicle on public

streets, roads and highways.

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SAFETY

Operator Safety

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow

proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp

angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster

speeds.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or

rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to

changing terrain conditions.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover. Never attempt

wheelies, jumps, or other stunts. Avoid exhibition driving.

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures

for climbing hills as described in this owner's manual. See page 41.

Descending Hills Improperly

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for

traveling down hills as described in this owner’s manual. See page 41.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause a rollover. Always maintain a steady

speed when climbing a hill.

If all forward speed is lost:

• Apply the brakes.

• Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying

light brake pressure to control speed.

If you begin rolling downhill:

• Never apply engine power.

• Apply the brakes gradually until the vehicle is fully stopped.

• Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying

light brake pressure to control speed.

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SAFETY

Operator Safety

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of

control or accident. Always use the size and type of tires specified for your vehicle. Always maintain

proper tire pressure as described in the owner's manual and on safety labels.

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause

loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces.

Always slow down and use additional caution when operating on slippery surfaces.

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction

unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this

owner's manual. See page 39.

Operating on Frozen Bodies of Water

Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate

the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to

support the weight and moving force of the vehicle, you and your passengers, and your cargo, together

with any other vehicles in your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your

entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age

of 16, without a drivers license, or without proper training. This could result in an accident or rollover.

Always remove the ignition key when the vehicle is not in use.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle. Hot components can

cause burns and fire. Do not touch hot exhaust system components. Always keep combustible

materials away from the exhaust system. Use caution when traveling through tall grass, especially dry

grass, to avoid debris build-up around the exhaust system.

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FEATURES AND CONTROLS

Component Locations

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if

equipped) must be used by both operator and passengers at all times. Any illustrations

without cab nets are only to allow component identification. Always use the cab nets (or

doors).

Not all models come with all features. Refer to the specifications section on page 94.

ROPS Cab

Frame

Hip Bar

Console

Cargo Box

Headlights

Fuel Tank Cap

6X6 Storage Box

Radiator

Front Bumper/Brush Guard

Storage

Compartment

Tailgate

Upper Net

Latch

Cab

Net

Tailgate

Latch

Release

Net

Rod

Receiver

Hitch

CV Boot/Rear Caliper

Net Rod

Mount

Muffler (Spark Arrester)

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FEATURES AND CONTROLS

Console

Instrument

Cluster

Park Brake

Gear Selector

Lever

(Shifter)

Storage

Tray

Cup Holder

12V Auxiliary

Outlets

Storage

Compartment

Auxiliary Outlets

The 12-volt receptacles have spade connections on

the back that may be used to power an auxiliary

light or other optional accessories or lights. The

connections are behind the console, under the dash.

On CREW models, an additional receptacle is

located on the rear of the driver’s seat.

12V Accessory

Outlet

Gear Selector

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

Low gear is the primary driving range for the RANGER. High gear is intended for use on

hard-packed surfaces with light loads.

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the

desired gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause

transmission damage. Always shift when the vehicle is stationary and the engine is at idle.

Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your

dealer if you experience any shifting problems.

Using Low Range

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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FEATURES AND CONTROLS

Switches

Ignition Switch

AWD/Differential Switch

Ignition Switch

Light Switch

Mode Button

The ignition switch is a three-position, key-operated

switch. The key can be removed from the switch

when it is in the OFF position.

OFF

The engine is off. Electrical circuits are off,

except Acc, 12V.

Electrical circuits are on. Electrical equip-

ment can be used.

START Turn the key to the START position to

engage the electric starter. The key returns to

the ON position when released.

Mode Button

The MODE button is located on the instrument cluster. Use the MODE button to toggle

through mode options available in the instrument cluster. See pages 29-33.

Light Switch

The ignition switch key must be in the ON/RUN

position to operate the headlights. Press the top of the

rocker switch toward the dash to place the headlights

on high beam. Move the rocker switch to the center

position to place the headlights on low beam. Press

the bottom of the rocker switch to turn off the

headlights.

HIGH

LOW

OFF

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

AWD

• Differential Lock (2WD)

• Differential Unlock

Differential Lock

Press the top of the rocker switch to engage All

Wheel Drive (AWD). See page 47 for operating

instructions.

Differential Unlock

Move the rocker switch to the center position to lock

the differential and operate in rear wheel drive. Press

the bottom of the switch to unlock the differential and allow the two rear drive wheels to

operate independently. See page 48 for differential lock operating instructions.

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FEATURES AND CONTROLS

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and

property damage, always heed the warnings and towing capacities outlined on pages 44-45.

Brake Pedal

Depress the brake pedal to slow or stop the vehicle. Apply

the brakes while starting the engine.

Throttle

Pedal

Brake

Pedal

Throttle Pedal

Push the throttle pedal down to increase engine speed.

Spring pressure returns the pedal to the rest position when

released. Always check that the throttle pedal returns

normally before starting the engine. Make sure there's

adequate throttle pedal freeplay. See page 78 for throttle

pedal adjustment procedures.

Adjustable Steering Wheel

The steering wheel can be tilted upward or downward

for rider preference.

Lift and hold the adjustment lever toward you while

moving the steering wheel upward or downward.

Release the lever when the steering wheel is at the

desired position.

Electronic Power Steering (EPS)

Electronic power steering (if equipped) engages when

the ignition key is turned to the ON position. EPS

remains engaged whether the vehicle is moving or idle.

To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if

the key remains in the ON position. The EPS warning indicator will illuminate to indicate the

EPS has shut down. Turn the key off and on to reset the unit.

See page 29 for EPS Warning Indicator information.

Fuel Cap

The fuel tank filler cap is located on the right-hand side

of the vehicle near the passenger seat. When refueling,

always use either leaded or unleaded gasoline with a

minimum pump octane number of 87 R+M/2 octane. Do

not use fuel with ethanol content greater than 10 percent,

such as E-85 fuel.

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FEATURES AND CONTROLS

Park Brake Lever

To help prevent the vehicle from rolling, engage the

park brake when parking the vehicle. When the park

brake is fully engaged, “BRAKE” appears in the rider

information display. Engine speed is limited to 1300

RPM in all gears, except neutral. If throttle is applied,

this limiting feature prevents operation, which protects

the park brake pads from excessive wear.

Trip 1

RPM

8888

Tip: This feature will not operate properly if the park brake connector or switch (under the hood)

malfunctions or becomes disconnected, or if the switch has moved. Check for disconnection, then

see your dealer promptly if this feature fails to operate properly.

Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100

hours thereafter to ensure proper cable tension. See page 80.

Always apply the service brakes before engaging or

releasing the park brake.

1. Apply the brakes.

2. Pull the park brake lever downward as far as

possible.

3. To release the park brake, apply the brakes. Press

the park brake release inward and move the lever

upward as far as possible.

WARNING! Operating the vehicle while the park brake is

engaged could cause loss of control and result in serious

injury or death. Always disengage the park brake before

operating the vehicle.

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FEATURES AND CONTROLS

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of

serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be

used by both operator and passengers at all times. Make sure all latches are secure before

operating the vehicle.

Always inspect cab nets and latches for tightness, wear and damage before each use of the

vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or

damaged cab nets and latches with new cab nets and latches. Please see your authorized

POLARIS dealer.

Securing a Net

Latch

1. After entering the vehicle, insert the lower net rod

into the net mount on the floor. Make sure the ball at

the end of the rod is properly secured in the mount.

2. Connect the latch at the top edge of the net to the

receiver latch mounted on the front frame.

Rod

Opening a Net

1. To exit the vehicle, release the latch at the top front edge

of the cab net.

2. Rotate the net rearward and pull upward on the lower net

rod to remove it from the mount.

3. Allow the net to hang freely outside the vehicle while

dismounting.

Net Mount

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FEATURES AND CONTROLS

Seat Removal

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

sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until

the pins are fully seated into the grommets.

Seat Belts

This POLARIS vehicle is equipped with three-point lap and

diagonal seat belts on all seats. Always make sure the seat belts

are secured for all riders before operating.

WARNING! Falling from a moving vehicle could result in serious

injury or death. Always fasten your seat belt securely before operating

or riding in the RANGER.

Latch Plate

Buckle

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch downward and across your chest

toward the buckle at the inner edge of the seat. The belt

should fit snugly across your hips and diagonally across

your chest. Make sure the belt is not twisted.

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

3. Release the strap, it will self-tighten.

4. To release the seat belt, press the square red button in the

buckle's center.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the

vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly

into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including

cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not

operate properly, have the seat belt system checked and/or replaced by an authorized

POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.

Do not use bleach, dye or household detergents.

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FEATURES AND CONTROLS

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover

performance requirements. Always have your authorized POLARIS dealer thoroughly

inspect the ROPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover. Always follow all safe

operating practices outlined in this manual to avoid vehicle rollover.

WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner

that could result in vehicle rollover.

Storage Compartments

A storage compartment is located under the driver’s seat, and on CREW models, under the

left rear seat. On 6X6 models, a lockable storage box is located behind the ROPS. Always

make sure the cover is securely latched before operating. The box is accessible from both

sides of the vehicle.

ROPS

(all models)

6X6 Storage

Box

Small Storage

Compartment

(left side only)

Large Storage

Compartment

(CREW only)

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FEATURES AND CONTROLS

Instrument Cluster

Speedometer

Indicator

Lamps

High water pressure may

damage components. Wash the

vehicle by hand or with a

garden hose using mild soap.

Do not use alcohol to clean the

instrument cluster. Do not

allow insect sprays to contact

the lens.

Speedometer

The speedometer displays

vehicle speed in either miles

per hour (MPH) or kilometers

per hour (km/h). See page 31.

Rider

Information

Center

MODE

Button

Indicator Lamps

Lamp

Indicates

Condition

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Vehicle Speed

Over Temperature

EPS Warning

This lamp illuminates to indicate an overheated engine. If the

indicator flashes, the overheating condition remains, and the system

will automatically reduce engine power.

This indicator illuminates briefly when the key is turned to the ON

position. If the light remains on, the EPS system is inoperative. See

your authorized POLARIS dealer for service.

Neutral

This lamp illuminates when the transmission is in neutral and the

ignition key is in the ON position.

High Beam

Helmet/Seat Belt

This lamp illuminates when the headlamp switch is set to high beam.

This lamp flashes for several seconds when the key is turned to the

ON position. The lamp is a reminder to the operator to ensure all

riders are wearing helmets and seat belts before operating.

Check Engine

This indicator appears if an EFI-related fault occurs. Do not operate

the vehicle if this warning appears. Serious engine damage could

result. See your dealer.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is

located in the instrument cluster. All

segments will light up for one

second at start-up. If the instrument

cluster fails to illuminate, a battery

over-voltage may have occurred

and the instrument cluster may have

shut off to protect the electronic

speedometer. If this occurs, take the

vehicle to your POLARIS dealer for

proper diagnosis.

Trip 1

RPM

8888

The information center is set to

display standard units of

measurement and a 12-hour clock at

the factory. To change to metric

and/or a 24-hour clock, see page 31.

7 6

1. Gear Indicator - This indicator displays gear shifter position.

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

-- = Gear Signal Error (or shifter between gears)

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.

When the last segment clears, a low fuel warning is activated. All segments including

the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See

your dealer.

3. Information Display Area - This area displays odometer, trip meter, engine hour meter

and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an

RPM too low to keep the battery charged. It may also occur when the engine is at idle

and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher

RPM or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 31 for

resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service

interval has been reached. The vehicle should be brought to your dealer for scheduled

maintenance. See page 31 for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is

on 4X4).

8. Turf Mode Indicator - This indicator illuminates when the operator unlocks the

differential. See page 48.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the information area options.

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to

the odometer display.

Standard Display

Metric Display

Kilometers

Distance

Fuel

Miles

U.S. Gallons

Fahrenheit

Liters, Imperial Gallons

Celsius

Temperature

Time

12-Hour Clock

24-Hour Clock

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON position.

3. When the display flashes the distance setting, tap the MODE button to advance to the

desired setting.

4. Press and hold the MODE button to save the setting and advance to the next display

option.

5. Repeat the procedure to change remaining display settings.

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or discharged.

1. Turn the key to the ON position. Use the MODE button to toggle to the odometer

display.

2. Press and hold the MODE button until the hour segment flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. To reset,

select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In

the Rider Information Center, the trip meter display contains a decimal point, but the

odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity,

temperature and elevation.

Programmable Service Interval

When the hours of engine operation equal the programmed service interval setting, the

wrench icon will flash for 5 seconds each time the engine is started. When this feature is

enabled, it provides a convenient reminder to perform routine maintenance. The service

interval is programmed at 50 hours at the factory. Use the following procedure to change the

service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours

to the desired setting (including OFF). Press and hold the MODE button to set the new

service hour interval.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only. Please see your

POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator activates

after the key has been turned on. Leave the key on if you want to view the active code

(failure code).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning

indicator is no longer active. This allows the determination of persistent as well as

intermittent faults.

Inactive codes are stored in the history of the unit.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

Suspect Parameter

Error Code

The error screen displays only when the

CHECK ENGINE light is on or when it goes

on and off during one ignition cycle. Error

codes are not stored. When the key is turned

OFF, the code and message is lost, but will

reappear if the fault reoccurs after restarting the

engine.

Number (SPN)

Number (0-9)

If the CHECK ENGINE light illuminates,

retrieve the error codes from the display.

1. If the error codes are not displayed, use the

MODE button to toggle until “Ck ENG”

displays on the main line of the display.

Failure Mode Indicator (FMI)

2. Press and hold the MODE button to enter

the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See an authorized POLARIS dealer for code details and diagnosis.

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OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover,

which may result in serious injury or death. Read and understand all safety warnings outlined in the

safety section of this owner’s manual.

Break-In Period

The break-in period for your new RANGER is the first twenty hours of operation, or the time

it takes to use the first two tanks full of fuel. No single action on your part is as important as

a proper break-in period. Careful treatment of a new engine will result in more efficient

performance and longer life for the engine. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts. Do not operate at full throttle or high speeds for extended periods during the

first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with fuel. Review the fuel warnings on page 18.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the

normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride

inspection checklist. See page 35. During the break-in period, change both the oil and

the filter at 25 hours.

6. Pull only light loads.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation

and every 100 hours thereafter.

8. Inspect and adjust park brake cable tension after the first 25 hours of operation and every

100 hours thereafter to ensure proper cable tension. See page 80.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better

performance. Break in the clutches and belt by operating at slower speeds during the break-

in period as recommended. Pull only light loads. Avoid aggressive acceleration and high

speed operation during the break-in period.

If a belt fails, always clean any debris from the duct and from the engine compartment.

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OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating

increases the risk of an accident. Always inspect the vehicle before each use to make sure it's

in safe operating condition.

Item

Remarks

Page

Brake system/pedal travel

Ensure proper operation

Brake fluid

Ensure proper level

Front suspension

Rear suspension

Steering

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Inspect, ensure tightness

Ensure proper levels

Wheels/fasteners

Frame nuts, bolts, fasteners

Fuel and oil

Coolant level

Ensure proper level

Inspect for leaks

Coolant hoses

Throttle

Ensure proper operation

Ensure operation

Indicator lights/switches

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation, apply POLARIS dielectric grease

when lamp is replaced

Brake light/tail lamp

Seat Belts

Check operation, apply POLARIS dielectric grease

when lamp is replaced

Check length of belt for damage, check latches for

proper operation

Cab nets (or doors)

Check for wear or damage, ensure proper installation

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OPERATION

Starting the Engine

1. Always start the engine outdoors or in a well-ventilated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors).

3. Apply the brakes. Engage the park brake.

4. Shift the transmission to neutral.

5. Do not press the throttle pedal while starting the engine. Turn the ignition key past the

ON/RUN position to START. Engage the starter for a maximum of five seconds. Release

the key when the engine starts.

6. If the engine does not start within five seconds, release the ignition switch and wait five

seconds. Repeat steps 5 and 6 until the engine starts.

7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles

smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the

engine to warm up for several minutes before operating the vehicle.

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Turn the engine off.

3. Engage the park brake.

WARNING! A rolling vehicle can cause serious injury. Always engage the park brake after stopping the

engine.

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

3. Practice starting and stopping (using the brakes) until you're familiar with the controls.

Tip: When the throttle pedal is released completely and the engine speed drops near an idle, the

vehicle has no engine braking.

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OPERATION

Driving Procedure

1. Wear a helmet, eye protection,

gloves, long-sleeve shirt, long

pants and over-the-ankle boots.

2. Perform the pre-ride

inspection. See page 35.

3. Sit in the driver's seat and

fasten the seat belt.

4. Always use the cab nets (or

doors) while riding in this

vehicle.

5. Start the engine and allow it to

warm up.

6. Apply the service brakes and

shift the transmission into gear.

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

8. Release the park brake.

9. Keeping both hands on the steering wheel, slowly release the brakes and depress the

throttle with your right foot to begin driving.

10. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

11. Do not carry a passenger until you have at least two hours of driving experience with this

vehicle.

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OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 35.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and

safely sit in a passenger seat with the seat belt secured, put both feet on the floor and

grasp the hand hold.

3. Make sure all passengers are wearing helmet, eye protection, gloves, long-sleeve shirt,

long pants and over-the-ankle boots.

4. Make sure all passengers secure their seat belt.

5. Make sure all cab nets (or doors) are properly secured.

6. Do not carry more than the recommended number of passengers for your vehicle. See

page 10.

7. Allow a passenger to ride only in a passenger seat.

8. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills,

and operating conditions. Avoid unexpected or aggressive maneuvers that could cause

discomfort or injury to a passenger.

9. Vehicle handling may change with a passenger and/or cargo on board. Allow more time

and distance for braking.

10. Always follow all operating guidelines as outlined on safety labels and in this manual.

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OPERATION

Driving on Slippery Surfaces

WARNING

Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When

operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to

reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing

weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down before entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns,

which can cause skids.

4. Engage all-wheel drive before wheels begin to lose traction.

NOTICE: Severe damage to the drive train may occur if the AWD is engaged while the wheels are

spinning. Always allow the wheels to stop spinning before engaging AWD.

5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the

brakes during a skid.

Turn in

direction of

skid

Sideways

skid

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OPERATION

Driving Over Obstacles

Follow these precautions when operating

over obstacles:

1. Always check for obstacles before

operating in a new area.

2. Look ahead and learn to read the terrain.

Be constantly alert for hazards such as

logs, rocks and low hanging branches.

3. Travel slowly and use extra caution

when operating on unfamiliar terrain.

Not all obstacles are immediately

visible.

4. Avoid operating over large obstacles

such as large rocks and fallen trees. If

unavoidable, use extreme caution and

operate slowly.

5. Always have all passengers dismount and move away from the vehicle before operating

over an obstacle that could cause a rollover.

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OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid excessively steep hills.

3. Keep both feet on the floor.

4. Always check the terrain carefully before

ascending any hill.

5. Never climb hills with excessively slippery or

loose surfaces.

6. Proceed at a steady rate of speed and throttle

opening. Never open the throttle suddenly.

7. Never go over the crest of a hill at high speed.

An obstacle, a sharp drop, or another vehicle

or person could be on the other side of the hill.

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or

rollover. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

Driving Downhill

When driving downhill, follow these

precautions:

1. Avoid excessively steep hills.

2. Drive straight downhill. Avoid descending

a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel

straight downhill when possible.

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

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OPERATION

Driving Through Water

Your POLARIS RANGER can operate through water up to a maximum recommended depth

equal to the floorboards.

NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly.

After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's

impossible to bring the vehicle to your dealer before starting the engine, perform the service

outlined on page 76, and take the vehicle to your dealer at the first opportunity.

Follow these procedures when operating

through water:

1. Determine water depths and current

before entering water.

2. Choose a crossing where both banks

have gradual inclines.

3. Proceed slowly, avoiding rocks and

obstacles.

4. Avoid operating through deep or fast-

flowing water.

WARNING! The large tires on your RANGER

may cause the vehicle to float in deep or fast-

flowing water, which could result in loss of

control and lead to serious injury or death.

Floorboard

Never cross deep or fast-flowing water with your

RANGER.

5. After leaving water, always dry the

brakes by applying light pressure to the

pedal repeatedly until braking action is

normal.

NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the

Periodic Maintenance Chart beginning on page 59. Give special attention to engine oil,

transmission oil, all gearcase fluids, and all grease fittings.

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OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the

vehicle. Always inspect left and right fields of

vision before backing.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

Parking the Vehicle

1. Apply the brakes. Stop the vehicle on a level

surface.

2. When parking inside a garage or other structure, be sure that the structure is well

ventilated and that the vehicle is not close to any source of flame or sparks, including

any appliance with pilot lights.

3. Turn the engine off.

4. Engage the park brake.

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

Parking on an Incline

Avoid parking on an incline if possible. If it's

unavoidable, follow these precautions:

1. Apply the brakes.

2. Place the transmission in gear.

3. Engage the park brake.

4. Turn the engine off.

5. Block the rear wheels on the downhill side.

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OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability,

which can result in serious injury or death. Always follow these precautions when hauling cargo:

Never exceed the maximum weight capacity of the vehicle. When determining the weight you are

adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or

box and the load on the trailer tongue. The combined weight of these items must not exceed the

maximum weight capacity.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

Always load the cargo box with the load as far forward and as low as possible.

When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving

conditions.

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

Slow down and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating

conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered

loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach

the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when

applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and

maneuverability may be adversely affected, causing vehicle rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10

MPH (16 km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5

MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a

hill.

Load Capacity

The RANGER has been designed to carry or tow specific capacities. Always read and

understand the load distribution warnings listed on the warning labels. The total load

(operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum

weight capacity of the vehicle. See page 12.

WARNING! Driving with passengers in the cargo box can

result in severe injury or death. Never allow passengers to

ride in the cargo box. Passengers must always ride in the

cab with seat belts fastened securely.

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OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake

instability. Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. Always shift to low gear for towing.

3. When towing a disabled RANGER vehicle, place the disabled vehicle’s transmission in

neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

4. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 44.

Towing a trailer increases braking distance.

5. Do not tow more than the recommended weight for the vehicle. See the towing capacity

chart below and the specifications charts beginning on page 94.

6. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other

location or you may lose control of the vehicle.

7. Never tow a trailer on a grade steeper than 15°.

Model

Total Towed

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

RANGER 4x4

RANGER 6x6

RANGER CREW

2000 lbs. (907 kg)

850 lbs. (386 kg)

150 lbs. (68.1 kg)

10 MPH (16 km/h)

Belt Life

To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

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OPERATION

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. Apply the brakes. Place the transmission in

gear. Engage the park brake.

3. Dismount the vehicle.

4. Ensure that the cargo is positioned evenly or

toward the front of the cargo box.

5. Release the tailgate by pulling up on the

tailgate latch.

WARNING! If the weight distribution on the box is

located toward the rear of the box when the release

lever is pulled forward, the box may dump unexpectedly

and cause serious injury to the operator or bystanders.

Never operate the dump lever without ensuring that the

load is positioned evenly or at the front of the box.

Release Lever

6. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box to

dump the cargo.

7. Lower the cargo box and push down securely to latch.

WARNING! Operating the vehicle while the cargo box is raised could result in severe injury. The box

could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the

rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate

this vehicle with the cargo box in the raised position.

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OPERATION

All Wheel Drive (AWD)

Engaging AWD

Press the top of the switch to engage All Wheel Drive

(AWD). The 4X4 indicator illuminates in the rider

information center to indicate that the vehicle is in

AWD. See page 30.

AWD

Differential Lock

Differential Unlock

When the AWD switch is on, the front wheels will

automatically engage any time the rear wheels lose

traction. When the rear wheels regain traction, the

front wheels will automatically disengage. There is

no limit to the length of time the vehicle may remain

in AWD.

Tip: The AWD switch may be turned on or off while the vehicle is moving.

Engage the AWD before getting into conditions where front wheel drive may be needed. If

the rear wheels are spinning, release the throttle before switching to AWD.

NOTICE: Switching to AWD while the rear wheels are spinning may cause severe drive shaft and

clutch damage. Always switch to AWD while the rear wheels have traction or are at rest.

Disengaging AWD

Move the AWD switch to the center or bottom position to disengage AWD. If the switch is

turned off while the front hubs are driving, they will not release until the rear wheels regain

traction.

In some situations, the front gearcase may remain locked after turning the AWD switch off.

If this occurs, you may notice increased steering effort and some vehicle speed restriction.

Perform the following procedure to unlock the front gearcase.

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet (3 m).

3. Stop completely.

4. Shift into low gear and drive forward.

5. If the front gearcase remains locked after following these instructions, see your dealer

for service.

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OPERATION

All Wheel Drive (AWD)

Locking the Differential

NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high

speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before

engaging the differential.

Locking the differential in slippery or low traction conditions helps improve traction. Move

the rocker switch to the center position (2WD) to lock the differential and operate in rear

wheel drive. On 6X6 models, all four rear wheels will be drive wheels.

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to

operate independently. This mode of operation is well suited to turf driving or whenever

aggressive traction is not required. On 6X6 models, the center wheels will remain drive

wheels.

6X6 Models

4X4 Models

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WINCH GUIDE

These safety warnings and instructions apply if your vehicle came equipped with a winch or

if you choose to add an accessory winch to your vehicle.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and

warnings in this manual.

Your winch may have a cable made of either wire rope or specially designed synthetic rope.

The term “winch cable” will be used for either unless noted otherwise.

Winch Safety Precautions

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook

when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the

Shock Loading section on page 56.

7. Always keep the area around the vehicle, winch, winch cable and load clear of people

(especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the

winch drum at all times. The friction provided by this wrapped cable allows the drum to

pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in

place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much

as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s

centerline whenever possible.

12. If winching at an angle is unavoidable, follow these precautions:

A. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one

end of the winch drum. Too much winch cable at one end of the winch drum can damage the

winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 54 to feed and rewind the cable

evenly before continuing the winch operation.

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WINCH GUIDE

Winch Safety Precautions

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and

possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45

seconds, or if the winch stalls during operation, stop winching and permit the winch to

cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while

winching a load.

17. Never let the winch cable run through your hands, even if

wearing heavy gloves.

18. Never release the clutch on the winch when the winch cable is

under load.

19. Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Take your winch to your dealer for

service if this occurs.

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage to winch

components.

24. Unplug the remote control from the vehicle when the winch is not in use to prevent

inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that

will shorten the life of the cable.

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WINCH GUIDE

Winch Operation

Read the Winch Safety Precautions in the preceding pages before using your winch.

Tip: Consider practicing the operation and use of your winch before you actually need to use it in the

field.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and

warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able to deal with. Do not be

afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of

damage or parts in need of repair or replacement before each use. Pay particular

attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has

been used) for lifting an accessory plow assembly. Promptly replace any worn or

damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s park brake and/or

park mechanism to hold the vehicle in place

during winching. Use wheel chocks if needed.

Hook Strap

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WINCH GUIDE

Winch Operation

4. Always use the hook strap when handling the hook.

WARNING! Never put your fingers into the hook. This could lead

to SEVERE INJURY.

A. Attach the hook itself onto the load or use a tow strap or

chain to secure the load to the winch cable.

Tip: A “tow strap” is NOT intended to stretch. A “recovery strap”

YES

is designed to stretch.

WARNING! Never use a recovery strap when winching due to

the excessive energy that can be released if the winch cable breaks. This can result in SEVERE

INJURY or DEATH. See the Shock Loading section on page 56.

B. Never hook the winch cable back onto itself. This will damage the winch cable and may result

in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or

DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the

cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will

help the spooling of the winch cable and reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid

damaging the tree during winch operation. Sharp cables and chains can damage and even kill

trees. Please remember to TreadLightly® (treadlightly.org).

E. Before operating the winch, be sure that the safety latch on

the winch cable hook is fully seated when the load is

attached.

F. Never operate your winch with a damaged hook or latch.

Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

YES

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the

winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable

are wrapped around the winch drum at all times. The friction provided by this wrapped

cable allows the drum to pull on the winch cable and move the load.

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WINCH GUIDE

Winch Operation

8. Read and adhere to the following information for winch damping to ensure safe winch

use.

A. In order to absorb energy that could be released by a winch cable failure, always place a

“damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense

object. A damper can absorb much of the energy released if a winch cable breaks when

winching. Even a tree limb can help as a damper if no other items are available to you.

B. Lay the damper on top of the mid-point of the winch cable length that is spooled out.

C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned

to the new mid-point of the winch cable. Always release the tension on the winch cable before

repositioning the damper.

D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others

to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may

result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is

when that vehicle itself is stuck. The winch-equipped vehicle should NEVER be in

motion to “shock” load the winch cable in an attempt to move a second stuck vehicle.

See the Shock Loading section on page 56. For your safety, always follow these

guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch cable.

B. Align the winch cable as close as possible to the winching vehicle’s centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following

instructions in this manual.

D. Re-engage the clutch on the winch.

E. Slowly winch in the slack in the winch cable.

F. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.

G. Shift to the lowest gear available on the stuck vehicle.

H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.

I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the

winch.

J. Detach the winch cable hook.

K. Rewind the winch cable evenly back onto the winch drum following the instructions in this

manual.

12. Never attempt to winch another stuck vehicle by attaching the winch cable to a

suspension component, brush guard, bumper or cargo rack. Vehicle damage may result.

Instead, attach the winch to a strong portion of the vehicle frame or hitch.

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WINCH GUIDE

Winch Operation

13. Extensive winching will run down the battery on the winching vehicle. Let the winching

vehicle’s engine run while operating the winch to prevent the battery from running low if

winching for long periods.

14. The winch motor may become hot during winch use. If you winch for more than 45

seconds, or if the winch stalls during operation, stop winching and permit the winch to

cool down for 10 minutes before using it again.

15. After winching is complete, especially if winching at an angle, it may be necessary to re-

distribute the winch cable across the winch drum. You will need an assistant to perform

this task.

A. Release the clutch on the winch.

B. Feed out the winch cable that is unevenly bunched up in one area.

C. Re-engage the winch clutch.

D. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the

hook strap.

E. Slowly winch the cable in while your assistant moves the end of the winch cable back and

forth horizontally to evenly distribute the winch cable on the drum.

F. Doing this reduces the chances of the winch cable “wedging” itself between lower layers of

winch cable.

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WINCH GUIDE

Winch Cable Care

For your safety, always replace POLARIS winch parts (including the cable) with genuine

POLARIS replacement parts available at your authorized POLARIS dealer.

WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or loose parts including

mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch

cable.

A. A kinked winch cable made of wire rope is shown at

right. Even after being “straightened out,” this cable has

already been permanently and severely damaged.

Promptly discontinue use of a winch cable in this

condition.

B. A kinked winch cable made of wire rope that has been

“straightened out” is shown at right. Even though it may

look usable, the cable has been permanently and

severely damaged. It can no longer transmit the load

that it could prior to kinking. Promptly discontinue use

of a winch cable in this condition.

C. A winch cable made of synthetic rope should be

inspected for signs of fraying. Replace the cable if

fraying is observed (shown at right). Promptly

discontinue use of a winch cable in this condition.

D. Also replace the winch cable if there are fused or

melted fibers. Such an area of the synthetic rope will

be stiff and appear smooth or glazed. Promptly

discontinue use of a winch cable in this condition.

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WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading.

Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of

a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other

bystanders.

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and

synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the

winch cable by moving the winching vehicle in an attempt to move an object. This is a

dangerous practice. It generates high winch cable loads that may exceed the strength of

the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load

on the winch, winch cable, and generates excessive heat from the motor. This is a form

of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch

produces shock loading of the cable even when towing at slow speeds. Towing from a

winch also positions the towing force high on the vehicle. This can cause instability of

the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and

can store energy. This stored energy in the recovery strap is released if a winch cable

fails making the event even more hazardous. Similarly, never use elastic “bungie” cords

for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This

type of use also causes shock loading that can cause damage to the winch, winch cable,

or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch

motor when operated from a stationary vehicle. Always remember that the winch and

winch cable are NOT designed for shock loading.

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WINCH GUIDE

Winch Maintenance and Service Safety

WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or

DEATH. Always follow all winch instructions and warnings in this manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable.

Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent

accidental activation of the winch

4. For your safety, always replace POLARIS winch parts (including the cable) with

genuine POLARIS replacement parts available at your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other winches use a specially

designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as

can be purchased in a hardware store. Although they may look similar, they are NOT

alike. A polymer rope not designed for winch use will stretch and store excessive energy

when winching.

WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy.

This will increase the chances of SEVERE INJURY or DEATH.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance

with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level

requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance

with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and

functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420.

Violations are subject to monetary penalties. Federal regulations can be viewed online at

www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to

the combustion chamber by the intake system. All exhaust gases exit through the exhaust

system.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system

controls fuel delivery. The engine and EFI components are set at the factory for optimal

performance and are not adjustable.

The emissions label is located on the frame under the seat.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active

or non-active implantable medical devices (such as heart monitoring or controlling devices)

should review the limitations of their device and the applicable electromagnetic standards

and directives that apply to this vehicle.

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MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable

condition. Inspection, adjustment and lubrication of important components are explained in

the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the

need for replacement parts, use genuine POLARIS parts available from your POLARIS

dealer.

Record maintenance and service in the Maintenance Log beginning on page 109.

Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe

service and adjustment procedures, have a qualified dealer perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more

frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate

contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level

begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine

the cause or see your dealer.

Maintenance Chart Key

Ź Perform these operations more often for vehicles subjected to severe use.

Emission-related service (Failure to conduct this maintenance will not void the

emissions warranty but may affect emissions.)

D Have an authorized POLARIS dealer perform these services.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Miles (Km)

Steering

Front suspension

Rear suspension

Tires

Brake fluid level

Brake pedal travel

Brake system

Pre-Ride

Make adjustments as need ed. See

Pre-Ride Checklist on page 35.

Wheels/fasteners

Frame fasteners

Engine oil level

Ź Air filter, pre-filter

Daily

Inspect; clean often; replace as needed

Drain deposits when visible

Ź Air box sediment tube

Coolant (if applicable)

Check level daily, change coolant every

2 years

Ź Power steering unit (if equipped)

Daily

Inspect daily; clean often

Headlamp/tail lamp

Check operation; apply dielectric

grease if replacing

Ź Air filter, main element

Weekly

Monthly

Inspect; replace as needed

Ź Brake pad wear

10 H

20 H

Inspect periodically

Battery

Monthly

Check terminals; clean; test

Inspect; replace if necessary

Ź Engine breather filter (if equipped) 25 H

Ź Engine oil change (break-in)

25 H

1 M

Perform a break-in oil change at one

month

Ź Front Gearcase oil (if equipped)

Ź Middle Gearcase oil (if equipped)

Ź Rear gearcase oil (if equipped)

Ź Transmission oil

25 H

50 H

1 M

3 M

6 M

Perform a break-in oil level check

Check tension, adjust

Park brake cable tension

Ź General lubrication

Shift Linkage

Lubricate all fittings, pivots, cables, etc.

Inspect, lubricate, adjust

Lubricate

D Steering

Ź Front Suspension

Lubricate

Ź Rear Suspension

Lubricate

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

D Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Miles (Km)

D Throttle cable/throttle pedal

50 H

6 M

Inspect; adjust; lubricate;

replace if necessary

E Throttle body air intake ducts/

50 H

6 M

Inspect duct for proper sealing/air leaks

flange

Drive belt

50 H

6 M

Inspect; adjust; replace as needed

Cooling system (if applicable)

Inspect coolant strength seasonally;

pressure test system yearly

Ź Oil lines, fasteners

Park brake cable tension

Ź Engine oil change

50 H

100 H

6 M

Inspect for leaks and loose fittings

Check tension, adjust

Perform a break-in oil change at one

month

Ź Oil filter change

100 H

6 M

Replace with oil change

Change fluid

Ź Front Gearcase oil (if equipped)

12 M

Ź Middle Gearcase oil (if equipped) 100 H

Change fluid

Ź Rear gearcase oil (if equipped)

100 H

Change fluid

Ź Transmission oil

Change fluid

D Fuel system

Check for leaks at tank cap, lines, fuel

valve, filter, pump, throttle body; replace

lines every two years

Ź Radiator (if applicable)

Ź Cooling Hoses (if applicable)

Ź Engine mounts

100 H

12 M

Inspect; clean external surfaces

Inspect for leaks

Inspect

Exhaust muffler/pipe

Inspect

D Spark plug

Inspect; replace as needed

D Ignition timing

100 H

12 M

Inspect

Ź Wiring

Inspect for wear, routing, security; apply

dielectric grease to connectors sub-

jected to water, mud, etc.

D Clutches (drive and driven)

100 H

12 M

Inspect; clean; replace worn parts

D Front wheel bearings

D Brake fluid

100 H

200 H

300 H

12 M

24 M

36 M

Inspect; replace as needed

Change every two years

Clean out

Spark arrester

Idle speed

Adjust as needed

D Toe adjustment

Inspect periodically; adjust when parts

are replaced

D Auxiliary brake (if equipped)

Inspect daily; adjust as needed

Headlight aim

Adjust as needed

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

D Have an authorized POLARIS dealer perform these services.

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MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance

Chart beginning on page 59, or more often under severe use, such as wet or dusty conditions.

Items not listed in the chart should be lubricated at the general lubrication interval.

Item

Lube

PS-4 5W-50 4-Cycle Oil

DOT 4 Brake Fluid

Method

Engine Oil

Brake Fluid

Add to proper level on dipstick. See page 63.

Maintain level between fill lines. See page 79.

Main Gearcase Oil

(Transmission)

AGL Gearcase Lubricant &

Transmission Fluid

See page 67 (6X6).

See page 66 (4X4/CREW).

Front Gearcase Oil

Demand Drive Fluid

ATV Angle Drive Fluid

U-Joint Grease

See page 68.

Middle Gearcase Oil (6X6)

Rear Gearcase Oil (6X6)

Prop Shaft U-joints (6X6)

Front Prop Shaft Yoke

See page 69.

See page 70.

Locate fittings and grease.

U-Joint Grease

Locate fittings and grease

(3 pumps maximum).

6X6 Prop Shaft U-Joints

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MAINTENANCE

Engine Intake Restrictor Plate

Some RANGER 800 models are equipped with an intake restrictor plate in order to meet

vehicle class regulations. This plate MUST NOT be removed for any reason. Removal of the

intake restrictor plate will void the warranty on the vehicle.

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance

Chart beginning on page 59. Always change the oil filter whenever changing oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause

accelerated wear and may result in engine seizure, accident, and injury. Always perform the

maintenance procedures as outlined in the Periodic Maintenance Chart.

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. See

page 100 for the part numbers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart

beginning on page 59. Always use the recommended engine oil.

Oil Check

The oil dipstick and fill tube is located on the engine.

1. Position the vehicle on a level surface.

Dipstick

2. Remove the seat and the underseat storage box.

3. Lift the lever lock to remove the dipstick. Wipe it dry

with a clean cloth.

4. Reinstall the dipstick completely, but do not lock it. The

dipstick must be screwed completely in to keep the angle

and depth of the stick consistent.

5. Remove the dipstick and check the oil level. Maintain

the oil level in the safe range. Do not overfill.

Tip: Due to the dipstick entry angle into the crankcase, the oil level

will read higher on the bottom side of the dipstick. Always read

the level on the upper surface of the dipstick.

Safe

Add

6. After reinstalling the dipstick, be sure to seat the lever

lock.

Safe

Range

7. Reinstall the underseat storage box and the seat.

Check Level

on Top Side

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MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart

beginning on page 59. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase.

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

5. Remove the drain plug.

6. Allow the oil to drain completely.

7. Reinstall the sealing washer on the drain plug. The sealing surfaces on drain plug and

crankcase should be clean and free of burrs, nicks or scratches.

8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).

9. Remove the seat and the underseat storage box.

10. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counter-

clockwise to remove it.

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

12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure

the o-ring is in good condition.

13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface,

then turn and additional 1/2 turn.

14. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil.

15. Shift the transmission to neutral.

16. Apply the brakes. Engage the park brake.

17. Start the engine. Allow it to idle for one to two minutes.

18. Stop the engine. Inspect for leaks.

19. Check the oil level on the dipstick and add oil as necessary to bring the level to the upper

mark on the dipstick.

20. Reinstall the underseat storage box and the seat.

21. Dispose of used filter and oil properly.

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MAINTENANCE

Gearcases

Gearcase Specification Chart

RANGER 4X4 Gearcase Specifications

Gearcase

Lubricant

Capacity

Fill Plug(s)

Torque

Drain Plug Torque

Main Gearcase

(Transmission)

AGL Gearcase

Lubricant &

Transmission Fluid

34 oz.

(1000 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase

Demand Drive Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

RANGER 6x6 Gearcase Specifications

Gearcase

Lubricant

Capacity

Fill Plug Torque Drain Plug Torque

Main Gearcase

(Transmission)

AGL Gearcase

Lubricant &

Transmission Fluid

43.6 oz.

(1290 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase

Middle Gearcase

Rear Gearcase

Demand Drive Fluid

ATV Angle Drive Fluid

9.3 oz.

8-10 ft. lbs.

11 ft. lbs.

(15 Nm)

(275 ml)

(11-13.6 Nm

6.75 oz.

(200 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

18 oz.

(532 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

RANGER CREW Gearcase Specifications

Gearcase

Lubricant

Capacity

Fill Plug(s)

Torque

Drain Plug Torque

Main Gearcase

(Transmission)

AGL Gearcase

Lubricant &

Transmission Fluid

34 oz.

(1000 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase

Demand Drive Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

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MAINTENANCE

Gearcases

Transmission (Main Gearcase) (4X4/CREW)

Always check and change the transmission oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59. Refer to the Gearcase Specifications Chart on

page 65 for recommended lubricants, capacities and torque specifications. See page 100 for

the part numbers of POLARIS products.

Oil Check

The fill plug is located on the rear of the gearcase. A level check/alternate fill plug is located

on the side of the gearcase. Maintain the oil level even with the bottom of the level check/fill

plug hole threads.

1. Position the vehicle on a level surface.

2. Remove the level check/fill plug. Check the oil level.

3. Remove the rear fill plug and add the recommended oil as needed.

4. Reinstall both fill plugs. Torque to specification.

Oil Change

The drain plug is located near the bottom of the gearcase.

1. Remove the rear fill plug and the level check/fill plug.

2. Place a drain pan under the gearcase.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended oil.

6. Reinstall both fill plugs. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

Rear Fill

Plug

Fill Level

Level Check and

Alternate Fill Plug

Drain Plug

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MAINTENANCE

Gearcases

Transmission (Main Gearcase) (6X6)

Always check and change the transmission oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59. Maintain the oil level even with the bottom of the

fill plug hole.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants,

capacities and torque specifications. See page 100 for the part numbers of POLARIS

products.

Oil Check

The fill plug is located at the rear of the vehicle.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

Fill

Plug

Oil Change

The drain plug is located on the bottom of the

transmission. Access the drain plug through the drain

hole in the skid plate.

1. Remove the fill plug.

Drain Plug

2. Place a drain pan under the drain plug. Remove the

drain plug. Allow the oil to drain completely.

3. Wipe the magnetic end of the drain plug clean to

remove accumulated metallic filings. Install a new

sealing washer.

4. Reinstall the drain plug. Torque to specification.

5. Add the recommended oil. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

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MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59. Maintain the oil level even with the bottom thread

of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants,

capacities and torque specifications. See page 100 for the part numbers of POLARIS

products.

Oil Check

The front gearcase fill plug is located on the right

side of the front gearcase.

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the oil level.

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely with a jackstand.

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

Fill

Plug

Drain

Plug

3. Remove the fill plug.

4. Place a drain pan under the drain plug on the

bottom right-hand side.

5. Remove the drain plug. Allow the oil to drain completely.

6. Clean and reinstall the drain plug. Torque to specification.

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks. Dispose of used oil properly.

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MAINTENANCE

Gearcases

Middle Gearcase (6X6)

Always check and change the middle gearcase oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59. Maintain the oil level even with the bottom thread

of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants,

capacities and torque specifications. See page 100 for the part numbers of POLARIS

products.

The middle gearcase fill plug is located on the side of the gearcase.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the oil level.

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the oil to drain

completely.

Fill Plug

4. Clean and reinstall the drain plug. Torque to

specification.

Drain Plug

5. Add the recommended fluid.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used oil properly.

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MAINTENANCE

Gearcases

Rear Gearcase (6X6)

Always check and change the rear gearcase oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants,

capacities and torque specifications. See page 100 for the part numbers of POLARIS

products.

The rear gearcase fill plug is on the driver's side of the rear gearcase.

Oil Check

Maintain the oil level even with the bottom thread

of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the oil level.

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Fill

Plug

Oil Change

1. Remove the fill plug.

Drain Plug

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 94 for the recommended spark plug

type for your vehicle. Always torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use

POLARIS-recommended spark plugs.

Spark Plug Gap/Torque

Model

Electrode Gap

New Plug Torque

Used Plug Torque

All

.035" (.9 mm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

Spark Plug Inspection

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.

CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when

removing a spark plug for inspection.

1. Remove the seat. Remove the spark plug cap.

2. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it

counterclockwise.

3. Reverse the procedure for spark plug installation. Torque to specification.

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits.

The electrodes are not burned or eroded. This indicates the proper type and heat range for the

engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an

improper spark plug or incorrect throttle body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a

carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of

fouling are excessive oil, use of non-recommended oil or incorrect throttle body adjustments.

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MAINTENANCE

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery

system components are the overflow bottle, radiator filler neck, radiator pressure cap and

connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced

out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant

temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past

the pressure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped

air. Observe coolant levels and maintain as recommended by adding coolant to the overflow

bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the

system be completely drained every two years and a fresh mixture of antifreeze and water

added. POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50

mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.

POLARIS Antifreeze is already premixed and ready to use. Do not dilute with water. See

page 100 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the freeze protection

required in your area.

Any time the cooling system has been drained for maintenance or repair, replace the coolant.

If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant

as needed.

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic

Maintenance Chart beginning on page 59. Do not obstruct or deflect air flow through the

radiator by installing unauthorized accessories in front of the radiator or behind the cooling

fan. Interference with the radiator air flow can lead to overheating and consequent engine

damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair

the radiator's effectiveness. Using a high-pressure system is not recommended.

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MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance

Chart beginning on page 59. Maintain the coolant level between the minimum and maximum

marks on the bottle (when the fluid is cool).

The overflow bottle is located in front of the right front wheel.

1. Position the vehicle on a level surface.

2. View the coolant level in the overflow bottle.

Radiator

Cap

Overflow

Bottle

3. If the coolant level is below the safe operating

range, lift the hood and locate the overflow bottle

lid. Remove the cap and use a funnel to add

coolant through the filler opening. Reinstall the

cap.

Tip: If coolant must be added often, or if the overflow bottle

runs completely dry, there may be a leak in the system.

Have the cooling system inspected by your POLARIS

dealer.

Radiator Coolant Level

1. Lift the hood.

CAUTION! Escaping steam can cause burns. Never

remove the pressure cap while the engine is warm or hot.

Always allow the engine to cool before removing the

pressure cap.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

Tip: This procedure is required only if the cooling system has been drained for maintenance and/or

repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the

recovery system to function properly. See your dealer for the correct replacement part.

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MAINTENANCE

POLARIS Variable Transmission (PVT) System

WARNING

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

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure

may occur at a high speed. The PVT system has been precision balanced. Any modification will cause

the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. As the

owner, you have the following responsibilities for your own safety and the safety of others:

• Always follow all recommended maintenance procedures. Always look for and remove debris inside

and around the clutch and vent system when replacing the belt.

• See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

Belt slip is responsible for creating excessive heat that destroys belts, wears clutch

components and causes outer clutch covers to fail. Switch to low range while operating at

slower speeds to extend the life of the PVT components (belt, cover, etc.).

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MAINTENANCE

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

If a belt fails, always clean any debris from the duct

and from the clutch and engine compartments when

replacing the belt.

WARNING! Failure to remove ALL debris when replacing

the belt could result in vehicle damage, loss of control and

severe injury or death.

1. Remove the seat and the underseat storage box.

2. Remove the clutch cover screws and open the

clutch cover. Remove all debris wrapped in and

around the PVT system.

3. Remove all debris from the entire clutch air duct

passage.

Remove ALL Debris

4. Check for signs of damage to seals on the transmission and engine. See your dealer

promptly for service if any seals appear to be damaged.

Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components

and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to

extend the life of the PVT components (belt, cover, etc.).

PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Use

the following instructions to dry it out before operating.

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

3. Apply the brakes. Start the engine.

4. Engage the park brake.

5. Shift the transmission to neutral.

6. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and

clutches. Do not hold the throttle wide open for more than 10 seconds.

7. Allow the engine RPM to settle to idle speed. Apply the service brakes. Release the park

brake and shift the transmission to the lowest available range.

8. Test for belt slippage. If the belt slips, repeat the process.

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

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MAINTENANCE

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined

below.

1. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Thoroughly dry the air pre-cleaner located under the hood.

4. Remove the spark plugs. Turn the engine over several times using the electric start.

5. Dry the spark plugs and reinstall, or replace with new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in

starting it or not.

8. If water has been ingested into the PVT follow the procedure on page 75 for drying.

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart

beginning on page 59. Service the air filter more frequently if the vehicle is operated in wet

conditions or at high throttle openings for extended periods.

1. Lift the cargo box to access the air

box.

Air Filter

2. Remove the air box cover and inspect

the gasket. It should adhere tightly to

the cover and seal all the way around.

Tip: Grasp the filter end to prevent damage to

the filter paper.

3. Remove the air filter.

4. Do not attempt to clean the main

element. Install a new air filter.

Tip: Apply a small amount of general purpose

grease to the sealing edges of the filter

before installing.

5. Inspect the air box for oil or water deposits. If present, drain into a suitable container.

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MAINTENANCE

Spark Arrester

WARNING

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or

death.

• Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures

can reach 1000° F. Allow components to cool sufficiently before proceeding.

• Remove any combustible materials from the area.

• Wear eye protection and gloves.

• Do not stand behind or in front of the vehicle while purging.

• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that

can cause loss of consciousness or death in a very short time.

• Never operate without the spark arrestor.

• Never go under the vehicle while it's inclined.

Use the following procedure to periodically purge accumulated carbon from the exhaust

pipe.

1. Remove the arrester clean-out plugs located on the

bottom of the muffler.

2. Place the transmission in neutral.

3. Engage the park brake.

4. Start the engine.

5. Purge accumulated carbon from the system by

momentarily revving the engine several times.

Exhaust

Outlet

6. If carbon is expelled, cover or plug the exhaust outlet

and rap on the pipe around the clean-out plugs while

revving the engine several more times.

Clean-Out

Plugs

7. If particles are still suspected to be in the muffler,

elevate the rear of the vehicle one foot higher than the front. Block the wheels.

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

9. Stop the engine. Allow the arrester to cool.

10. Reinstall the arrester plugs and remove the outlet cover or plug.

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MAINTENANCE

Throttle System

WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident and lead to

serious injury or death if the throttle pedal sticks during operation.

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

during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle

pedal. Immediately contact your dealer for service if throttle problems arise.

Throttle Freeplay Inspection

If the throttle pedal has excessive play due to cable stretch or

misadjustment, it will cause a delay in throttle response,

especially at low engine speed. The throttle may also not open

fully. If the throttle pedal has no freeplay, the throttle may be

hard to control, and the idle speed may be erratic.

Check the throttle pedal freeplay at the intervals outlined in the

Periodic Maintenance Chart beginning on page 59. Adjust the

freeplay if necessary.

Throttle

Pedal

1. Apply the brakes. Engage the park brake. Shift the

transmission to neutral.

2. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine begins to pick up speed.

Freeplay should be 1/16 to 1/8 inches (1.6-3.2 mm).

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see

your POLARIS dealer for adjustment.

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

3. Squeeze the end of the rubber boot and slide it far enough to

expose the end of the inline cable adjuster.

4. Loosen the adjuster lock nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3

Boot

mm) of freeplay is achieved at the throttle pedal. See page

78.

Tip: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the cable

Lock Nut

adjuster to its original position.

Adjuster

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MAINTENANCE

Brakes

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

page 24.

Brake Fluid

Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or

use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The

moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade

and the possibility of accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the

fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are

unknown.

1. Position the vehicle on a level surface.

Maximum

Minimum

2. View the brake fluid level at the reservoir in the driver’s

side wheel well.

3. The level should be between the upper (MAX) and

lower (MIN) level lines.

4. If the fluid level is lower than the upper level line, add

brake fluid to the upper (MAX) line.

5. Apply the brake forcefully for a few seconds and check

for fluid leakage around the fittings.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy

feel.

3. Check the friction pads for wear, damage and looseness.

4. Check brake discs for signs of cracks, excessive

corrosion, warping or other damage. Clean any grease

using an approved brake cleaner or alcohol.

WARNING! Do not apply WD-40 or any petroleum product to

brake discs. These types of products are flammable and may also

reduce the friction between the brake pad and caliper.

3/64" (1mm)

5. Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when

worn to 3/64" (1 mm).

Park Brake Inspection

Park Brake Release

1. Apply the brakes.

2. Pull the park brake lever downward as far as possible.

3. Check the vehicle for movement. The vehicle should

not roll while parked. If the vehicle moves, adjust the

park brake.

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MAINTENANCE

Brakes

Park Brake Adjustment

Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100

hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may

cause “BRAKE” to display in the rider information center, along with activation of the

limiting feature. If this occurs, move the park brake lever to the forward-most position, then

inspect and adjust park brake cable tension.

Tip: If performing this service is difficult due to conditions or location, open the hood and temporarily

disconnect the park brake connector. This will inactivate the limiting function. Reconnect the

connector as soon as possible, and adjust the park brake cable to proper tension.

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

3. Loosen or tighten the nuts on the lever end of the park brake cable as needed.

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at the intervals

outlined in the Periodic Maintenance Chart beginning on page 59.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right. There should be 0.8"-1.0" (20-25 mm) of

freeplay.

3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy,"

have the steering system inspected by an authorized POLARIS dealer.

Suspension Adjustments

The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.

1. Remove the top shock mounting bolts from the inside mounting holes.

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Spring Adjustment

Adjust the front and rear shock

absorber springs by rotating

the adjustment cam either

clockwise or counterclockwise

to increase or decrease spring

tension.

Outside Mounting Holes

Inside Mounting Holes

Rear Suspension Shown

Adjustment is similar for Front Suspension

Cam

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MAINTENANCE

Tires

WARNING

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly

installed tires will affect vehicle handling and could cause an accident resulting in serious injury or

death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on

the vehicle. Always use POLARIS-approved size and type of tires for this vehicle when replacing tires.

Tire Tread Depth

Always replace tires when tread depth is

worn to 1/8" (3 mm) or less.

1/8" (3 mm)

Axle and Wheel Nut Torque

Specifications

Inspect the following items occasionally for tightness, and if they've been loosened for

maintenance service.

Do not lubricate the stud or the lug nut.

Nut Type

Location

Nut Torque

Lug Nut

(Aluminum

Wheels)

Front and Rear

30 ft. lbs. (41 Nm) PLUS 1/4 TURN

Nut and Washer

(Steel Wheels)

Front and Rear

35 ft. lbs. (47 Nm)

Spindle Nut

Front

70 ft. lbs. (95 Nm)

Hub Retaining Nuts

Center and Rear

110 ft. lbs. (150 Nm)

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MAINTENANCE

Tires

Wheel Removal

1. Apply the brakes. Engage the park brake.

2. Stop the engine. Place the transmission in gear.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Apply the brakes.

2. Place the transmission in gear.

3. Engage the park brake.

4. 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.

WARNING! Improperly installed wheels can

adversely affect tire wear and vehicle handling, which

can result in serious injury or death. Always ensure

that all nuts are torqued to specification. Do not

service axle nuts that have a cotter pin installed. See

your POLARIS dealer.

5. Attach the wheel nuts and washers and finger tighten.

6. Carefully lower the vehicle to the ground.

7. Torque the wheel nuts to specification. See page 81.

Power Steering Unit

If your model is equipped with power steering,

frequently clean the areas around and on the power

Clean Often

steering unit to allow proper cooling. Clean these

areas thoroughly.

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MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses

become dirty during normal operation. Clean lights frequently and replace burned out lamps

promptly. Do not operate this vehicle at night or in low light conditions until the headlight is

replaced. Always make sure lights are adjusted properly for best visibility.

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin

leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement

1. Open the hood.

CAUTION! Hot components can cause burns to skin.

Allow lamps to cool before servicing.

Wiring Harness

2. Unplug the headlamp from the wiring

harness. Be sure to pull on the connector, not

on the wiring.

3. Turn the lamp counterclockwise to remove

it.

4. Install the new lamp.

Tip: Make sure the tab on the lamp locates properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

Brake Lights

When the brake pedal is depressed, the brake light comes on. Check the brake light before

each ride.

1. Turn the ignition switch to the ON position.

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

pedal travel. If the light doesn't come on, check the bulb.

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MAINTENANCE

Lights

Headlight Beam Adjustment

8" (20 cm)

25 ft.

(7.6 m)

1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from

a wall.

2. Place the transmission in gear. Engage the park brake.

3. Measure the distance from the floor to the center of the headlight and make a mark on

the wall at the same height.

4. Apply the brakes. Start the engine. Turn on the headlights.

5. Observe the headlight aim. The most intense part of the headlight beam should be aimed

8" (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat

while performing this step.

6. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

7. Loosen the screw, adjust the headlight, and tighten the screw.

8. Repeat steps 5-7 until the lamp is properly adjusted.

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MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse may

need replacement. Locate and correct any short circuits that may have caused the blown fuse,

then replace the fuse. Spare fuses are provided in the fuse box. The power steering fuse (if

equipped) is located on the power steering wiring harness near the fuse box.

If you suspect that a fuse or relay may not be working properly, please see your POLARIS

dealer.

Fuse

Feature Supported

20A

10A

20A

30A

Accessories, 12V Power Receptacle

Electronic Fuel Injection

Engine Control Module

Lights

Main Fuse - Ignition, Instrument Cluster

Power Steering (if equipped)

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MAINTENANCE

Battery

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with

skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable

oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging

or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF

REACH OF CHILDREN.

Your vehicle may have either a sealed battery, which requires little maintenance, or a

conventional battery. A sealed battery can be identified by its flat covers on the top of the

battery. A conventional battery has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary,

remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking

soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat

the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning

solution or tap water into the battery.

Battery Fluid (Conventional Battery)

Upper

Mark

Lower

Mark

A poorly maintained battery will deteriorate rapidly. Check the

battery fluid level often. Maintain the fluid level between the

upper and lower level marks.

Add only distilled water. Tap water contains minerals that are

harmful to a battery.

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MAINTENANCE

Battery

Battery Removal

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious

injury or death. When removing the battery, always disconnect the negative (black) cable first. When

reinstalling the battery, always connect the negative (black) cable last.

1. Remove the seat. Remove the storage bin.

2. Remove the screws from the battery hold-

down strap and remove the strap.

3. Disconnect the black (-) battery cable first.

4. Disconnect the red (+) battery cable last.

5. Lift the battery out of the vehicle. Be

careful not to tip a conventional battery

sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it

off with a solution of one tablespoon

baking soda and one cup water to

prevent damage to the vehicle.

Hold-Down Strap

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MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a

shorter life. It can also hinder vehicle performance. Follow the battery charging instructions

on page 89 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the

battery holder under the driver’s seat with

the terminals toward the rear of the

vehicle.

3. Connect and tighten the red (+) cable

first. Connect and tighten the black (-)

cable last.

4. Verify that cables are properly routed and

install the hold-down strap. Tighten the

screws securely.

Position Terminals

Toward Rear

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery

from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place.

Check battery voltage each month during storage and recharge as needed to maintain a full

charge. See page 89.

POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender

charger or by charging about once a month to make up for normal self-discharge. Battery

Tender can be left connected during the storage period, and will automatically charge the

battery if the voltage drops below a pre-determined point.

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MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking or spilled

electrolyte during charging. See page 87.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr

rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 88. Make sure the positive terminal is toward the front of

the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installation of a sealed battery.

Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at

the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully

charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a

voltmeter or multimeter to measure DC voltage.

WARNING! An overheated battery may explode, causing severe injury or death. Always watch

charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool

before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery

voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer's instructions for

recharging. When using a constant current charger, use the guidelines below for

recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at 3 mos. from date of

manufacture

None required

3-6 hours

75%-100%

May need slight charge, if no charge

given, check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less

Needs charge with desulfating charger

At least 20 hours

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also

extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle

by hand or with a garden hose, using mild soap.

NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of

mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts

last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

• Grease all zerk fittings immediately after washing. Allow the engine to run for a while to

evaporate any water that may have entered the engine or exhaust system.

If a high pressure water system is used for cleaning (not recommended), exercise extreme

caution. The water may damage components and could remove paint and labels. Avoid

directing the water stream at the following items:

• Wheel bearings

• Radiator

• Brakes

• Switches and controls

• Cab and body panels

• Labels and decals

• Electrical components and wiring

• Transmission seals

If an informational or graphic label becomes illegible or comes off, contact your POLARIS

dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no

charge.

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing

the finish on your POLARIS vehicle. Follow the instructions on the container.

• Avoid the use of automotive products, some of which can scratch the finish of your

vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

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MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by

fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 90.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the

instructions on the container for the recommended amount. Carbon Clean removes water

from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings,

valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the

entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 64.

Air Filter / Air Box

1. Inspect and clean or replace the pre-cleaner and air filter. See page 76.

2. Clean the air box.

3. Drain the sediment tube.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic

Maintenance Chart beginning on page 59.

Battery Maintenance

See page 88 for storage and charging procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance

Chart beginning on page 59.

• Front gearcase fluid

• Rear and Middle gearcase fluids (6X6)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the

container. Start the engine. Allow it to idle for several minutes so the Carbon Clean

reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes,

use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the pre-

measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from

the spark plug cavities into the hole at the front of the cylinder head, and appear to be an

oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 71.

4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto

the plugs.

5. Turn the engine over several times. Oil will be forced in and around the piston rings and

ring lands, coating the cylinder with a protective film of fresh oil.

6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should

be completely drained of gasoline.

Storage Area/Covers

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS

cover. Do not use plastic or coated materials. They do not allow enough ventilation to

prevent condensation, and may promote corrosion and oxidation.

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MAINTENANCE

Removal from Storage

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the

vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or

restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection section on page 35. Tightness

of the bolts, nuts and other fasteners should be checked by an authorized POLARIS

dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page

59.

Transporting the RANGER

Follow these procedures when transporting the vehicle.

1. Apply the brakes. Engage the park brake.

2. Stop the engine.

3. Place the transmission in gear.

4. Secure the fuel cap, oil cap, hood and seat. Ensure that the seats are attached correctly

and are not loose.

WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or

remove all cargo, and inspect the unit for loose parts prior to transport.

5. Always tie the frame of the RANGER to the transporting unit securely with suitable

straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

6. Remove the key to prevent loss during transporting.

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SPECIFICATIONS

RANGER 800 EFI/EPS

Maximum Weight Capacity

Dry Weight

1500 lbs. (681 kg) (including operator, passenger, cargo, accessories)

1100 lbs. (499 kg) (Models sold in California)

1237 lbs. (561 kg)

Test GVW - Rollover Protection 2940 lbs. (1333.5 kg) per OSHA 29 CFR 1928.53

System (ROPS)

Fuel Capacity

8.8 gal. (33.3 l)

1.9 qts. (1.8 l)

3.25 qts. (3 l)

Engine Oil Capacity

Coolant Capacity

Towing Capacity

2000 lbs. (907 kg)

150 lbs. (68 kg)

Hitch Tongue Capacity

Max. Cargo Box Load*

1000 lbs. (454 kg)

600 lbs. (272 kg) (Models sold in California)

Overall Length

114 in. (289.6 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

60 in. (152.4 cm)

58 in. (147.3 cm)

76 in. (193 cm)

Wheelbase

76 in. (193 cm)

Cargo Box Dimensions (Inside)

Ground Clearance

Min. Turning Radius

Engine

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

11.5 in. (29.2 cm)

158 in. (401 cm)

4 valve 4 stroke twin cylinder with counter balance

760 cc

Displacement

Bore x Stroke

80 x 76.5

Alternator Output

Compression Ratio

Starting System

Fuel System

500 W @ 3000 RPM

10.0:1

Electric

Electronic Fuel Injection

Bosch EFI ECU Controlled

RC7YC3 /.035 in. (0.9 mm)

Dual A-arm w/9.6 in. (24.4 cm) of travel

Independent w/9 in. (23 cm) of travel

Pressurized Wet Sump

Ignition System

Spark Plug / Gap

Front Suspension

Rear Suspension

Lubrication System

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SPECIFICATIONS

RANGER 800 EFI/EPS

Driving System Type

Shift Type

PVT, 4-wheel independent shaft, lockable differential

Single Lever (H/L/N/R)

7.70:1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Rear

Tire Size - Front

Tire Size - Rear

7.00:1

3.6:1

3.818:1

3.105:1

25 x 10 - 12 (26 x 9 - 12 for select models)

25 x 11 - 12 (26 x 11 - 12 for select models)

10 psi (69 KPa)

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Brake, Park

12 psi (83 KPa)

Foot Activated, 4 wheel hydraulic disc

Hand activated, mechanical

2 single beam, 50W, quartz/halogen

10 L.E.D. (.28W)

Hood Headlight

Taillights

Brake Light

10 L.E.D. (3.1W)

Clutching

See your POLARIS dealer for clutching specifications.

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SPECIFICATIONS

RANGER 6X6

Maximum Weight Capacity

Dry Weight

2000 lbs. (907 kg) (includes weight of operator, passenger, cargo, accesso-

ries)

1551 lbs. (703.5 kg)

Test GVW - Rollover Protection 3660 lbs. (1660 kg) per OSHA 29 CFR 1928.53

System (ROPS)

Fuel Capacity

8.8 gal. (33.3 l)

Engine Oil Capacity

Coolant Capacity

Towing Capacity

Max. Cargo Box Load

Overall Length

2 qts. (1.9 l)

3.25 qts. (3 l)

2000 lbs. (907 kg)

1250 lbs. (567 kg)

137 in. (348 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

60 in. (152.4 cm)

58 in. (147.3 cm)

76 in. (193 cm)

Wheelbase

105 in. (267 cm)

Cargo Box Dimensions (Inside)

Ground Clearance

Min. Turning Radius

Engine

42.5 x 54 x 11.5 in. (108 x 137 x 29 cm)

12 in. (30.5 cm)

243 in. (617 cm)

4 valve 4 stroke twin cylinder with counter balance

760 cc

Displacement

Bore x Stroke

80 x 76.5

Alternator Output

Compression Ratio

Starting System

Fuel System

500 W @ 3000 RPM

10.0:1

Electric

Electronic Fuel Injection

Bosch EFI ECU Controlled

RC7YC3 /.035 in. (0.9 mm)

Dual a-arm w/9.6 in. (24.4 cm) of travel

Independent w/9 in. (23 cm) of travel

Pressurized Wet Sump

Ignition System

Spark Plug / Gap

Front Suspension

Center Suspension

Rear Suspension

Lubrication System

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SPECIFICATIONS

RANGER 6X6

Driving System Type

Shift Type

PVT

Single Lever, Console (H/L/N/R)

8.71:1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Final

Tire Size - Front

7.91:1

3.85:1

3.818:1

3.70:1

25 x 10 - 12

Tire Size - Center/Rear

Tire Pressure - Front

Tire Pressure - Center/Rear

Brakes, Front/Rear

Brake, Park

25 x 11 - 12

10 psi (69 kPa)

12 psi (83 kPa)

Foot Activated, 4 wheel hydraulic disc

Hand activated, mechanical

2 single beam, 50W, quartz/halogen

10 L.E.D. (.28W)

10 L.E.D. (3.1W)

Hood Headlight

Taillights

Brake Light

Clutching

See your POLARIS dealer for clutching specifications.

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SPECIFICATIONS

RANGER CREW 800

Maximum Weight Capacity

Dry Weight

1750 lbs. (795 kg) (includes weight of operator, passengers, cargo, acces-

sories)

1495 lbs. (678 kg)

Test GVW - Rollover Protection 3360 lbs. (1524 kg) per OSHA 29 CFR 1928.53

System (ROPS)

Fuel Capacity

8.8 gal. (33.3 l)

Engine Oil Capacity

Coolant Capacity

Towing Capacity

Hitch Tongue Capacity

Max. Cargo Box Load

Overall Length

2 qts. (1.9 l)

1.6 gal. (6 l)

2000 lbs. (907 kg)

150 lbs. (68 kg)

1000 lbs. (454 kg)

145 in. (368 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

60 in. (152.4 cm)

58 in. (147.3 cm)

76 in. (193 cm)

Wheelbase

108 in. (274 cm)

Cargo Box Dimensions (Inside)

Ground Clearance

Min. Turning Radius

Engine

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

11.5 in. (29 cm)

255 in. (648 cm)

4 valve 4 stroke twin cylinder with counter balance

760 cc

Displacement

Bore x Stroke

80 x 76.5

Alternator Output

Compression Ratio

Starting System

500 W @ 3000 RPM

10.0:1

Electric

Fuel System

Electronic Fuel Injection

Bosch EFI ECU Controlled

RC7YC3 /.035 in. (0.9 mm)

Dual a-arm w/9.6 in. (24.4 cm) of travel

Independent w/9 in. (23 cm) of travel

Pressurized Wet Sump

Ignition System

Spark Plug / Gap

Front Suspension

Rear Suspension

Lubrication System

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SPECIFICATIONS

RANGER CREW 800

Driving System Type

Shift Type

PVT, 4-wheel independent shaft, lockable differential

Single Lever (H/L/N/R)

7.70:1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Final

Tire Size - Front

Tire Size - Rear

7.0:1

4.63:1

3.818:1

3.105:1

26 x 9 - 12

26 x 11 - 12

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Brake, Park

12 psi (83 KPa)

14 psi (97 KPa)

Foot Activated, 4 wheel hydraulic disc

Hand activated, mechanical

2 single beam, 50W, quartz/halogen

10 L.E.D. (.28W)

10 L.E.D. (3.1W)

Hood Headlight

Taillights

Brake Light

Clutching

See your POLARIS dealer for clutching specifications.

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POLARIS PRODUCTS

Part Number

Description

Engine Lubricant

Fogging Oil (12 oz./355 ml Aerosol)

2870791

2876244

2876245

PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)

PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l)

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)

Demand Drive Fluid (qt./.95 l)

2878068

2878069

2877922

2877923

2870465

Demand Drive Fluid (gal./3.8 l)

Pump for Gallon (3.8 l) Jug

Coolant

2871534

2871323

Polaris Antifreeze 60/40 Premix (qt./.95 l)

Polaris Antifreeze 60/40 Premix (gal./3.8 l)

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season

All Season Grease (3 oz./89 ml cartridge)

All Season Grease (14 oz./414 ml cartridge)

ATV Angle Drive Fluid (qt./.95 l)

2871312

2871322

2871423

2876160

2872276

2871460

2871515

2871551

2871329

ATV Angle Drive Fluid (2.5 gal./9.5 l)

Premium Starter Grease

U-Joint Grease (3 oz./89 ml cartridge)

U-Joint Grease (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel™)

Additives / Miscellaneous

2871326

2872189

2871956

Carbon Clean

DOT 4 Brake Fluid

Loctite™ 565 Thread Sealant

100

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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or tall

trailer in high range

Use low range during loading.

Starting out going up a steep

incline

Use low range. See warnings on page 41.

Driving at low RPM or ground

speed (3-7 MPH)

Drive at a higher speed or use low range more frequently.

Insufficient warm-up at low

ambient temperatures

Warm the engine at least 5 minutes. With the transmission in neutral,

advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The

belt will become more flexible and prevent belt burning.

Slow/easy clutch engagement

Use the throttle quickly and effectively.

Towing/pushing at low RPM/low Use low range only.

ground speed

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range and carefully use fast, aggressive throt-

tle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle roll-

over.

Climbing over large objects from Shift the transmission to low range and carefully use fast, brief, aggressive

a stopped position

throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle roll-

over.

Belt slippage from water or snow Dry out the PVT. See page 75. Inspect clutch seals for damage if repeated

ingestion into the PVT system

leaking occurs.

Clutch malfunction

See your POLARIS dealer.

Poor engine performance

Check for fouled plugs or foreign material in gas tank or fuel lines. See

your dealer.

Slippage from failure to warm up Always warm up the belt by operating below 30 MPH for one mile (5

belt

miles or more when temperature is below freezing).

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See pages 34 and 74.

101

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TROUBLESHOOTING

Park Brake Engine Limiting Feature Fails to Disengage

Possible Cause

Solution

Park brake is not completely disengaged

Ensure lever is in forward-most position

Park brake connector malfunction or switch move-

ment or failure

Disconnect the connector if temporary continued

operation is necessary, see your dealer promptly for

service

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Inspect, clean, reinstall connectors

Loose battery connections

Loose solenoid connections

Loose electronic control box connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plugs

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Immediately see your POLARIS dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Water present in fuel

Check all connections and tighten

Replace with fresh recommended fuel

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

102

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TROUBLESHOOTING

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Other mechanical failure

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel

Water is present in fuel

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Replace with new fuel

Inspect, clean and/or replace spark plug

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Other mechanical failure

Overheated engine

Clean radiator screen and core, clean engine exterior,

see your dealer

103

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WARRANTY

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED

WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship.

POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS

standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation

are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of

purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty

period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The

duration of this warranty may vary by international region based upon local laws and regulations.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to

POLARIS within ten days of purchase. 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 your proof of warranty coverage. If you have not signed the original registration and received the

customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED

UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your

vehicle is very important in ensuring 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

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or

workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This

warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.

This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified,

neglected, improperly maintained, or used for purposes other than for which it was designed.

This warranty excludes damages or failures resulting from: improper lubrication; improper engine timing;

improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or

abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other

foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or

unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty

period expires or by an unauthorized repair center.

104

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WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect

in materials or workmanship and provides no coverage for consumable components, general wear items, or any

parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were

not designed or not intended, including but not limited to the following items:

•

Wheels and tires

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Light bulbs/Sealed beam lamps

Filter

Lubricants

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components and fluids

Circuit breakers/Fuses

Electronic components

Spark plugs

Sealants

Coolants

Bearings

Bushings

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of

POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this

warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels,

meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of

profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION,

REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, 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 WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,

INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS

LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO

THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE

SIX MONTH WARRANTY PERIOD. P0LARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED

IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF

IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF

INCONSISTENT WITH CONTROLLING STATE LAW.

105

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WARRANTY

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting

warranty service you must present your copy of the Warranty Registration From 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.

In the country where your product was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are

traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be

requested from any authorized POLARIS dealer that sells the same line as your product.

Outside the country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased, you should take your

product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the

selling dealer’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be

authorized to perform the warranty repair.

If you move:

If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of

the destination country before you move. Product importation rules vary considerably from country to country.

You may be required to present documentation of your move to POLARIS in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS in order to register your product in

your new country. You should warranty register your product at a local POLARIS dealer in your new country

immediately after you move to continue your warranty coverage and to ensure that you receive information and

notices regarding your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the

product was originally purchased, all warranty coverage will be denied. You must nonetheless register your

product under your name and address with a local POLARIS dealer in your country to ensure that you receive

safety information and notices regarding your product.

EXPORTED PRODUCTS

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE

BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE

SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received

authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this product’s warranty or service coverage if you have any questions. This policy

does not apply to products registered to government officials or military personnel on assignment outside the

country of the selling dealer’s authorized location. This policy does not apply to Safety Bulletins.

NOTICE

If your product is registered outside of the country where it was purchased and you have not followed the

procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind,

other than safety bulletins. Products registered to Government officials or military personnel on assignment

outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance,

they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or

in different countries. If any of the above terms are void because of federal, state, local law, all other warranty

terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

106

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle.

POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is

designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission

regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would

cause it to fail to meet these regulations.

The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles starts on the date of

purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers

(3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The

warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original

retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of

vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions

warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the

vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional

warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts

may be covered subject to the terms of any such paid service contract or paid warranty extension.

This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions,

and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other

components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited

warranty does not cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emissions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

107

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or

replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS

LIMITED 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 WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT

OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES

IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY

FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO

THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty

lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty

does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty

also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing

competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire,

explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS

may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance

or use, by accidents for which POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on

your vehicle. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that

may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a

potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the

effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

California Residents

Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only the 50-state models are

certified for sale in California. The 50-state models available for sale in California are identified by the letter “C”

in the model name (e.g., R13UH88A_C). The POLARIS 50-state models are designed and built with features

such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable

California regulations and may void this limited emissions warranty offered by the manufacturer.

If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer

Assistance.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

108

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MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

109

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INDEX

Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Air Filter Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 76

All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 47-48

Disengaging AWD . . . . . . . . . . . . . . . 47

Component Locations . . . . . . . . . . . . . . . . . . . . . . 21

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Coolant Level, Overflow Bottle (Coolant) . . . . . . 73

Coolant Level, Radiator. . . . . . . . . . . . . . . . . . . . . 73

Coolant, Adding or Changing . . . . . . . . . . . . . . . . 72

Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 72-73

Crankcase Emission Control System. . . . . . . . . . . 58

Engaging AWD. . . . . . . . . . . . . . . . . . 47

Locking the Differential . . . . . . . . . . . 48

All Wheel Drive Switch. . . . . . . . . . . . . . . . . . . . 23

Arrester, Spark, Warning. . . . . . . . . . . . . . . . . . . 77

Auxiliary Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 22

Axle Nut Inspection. . . . . . . . . . . . . . . . . . . . . . . 81

Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 81

Differential Lock Switch . . . . . . . . . . . . . . . . . . . . 23

Differential Locking . . . . . . . . . . . . . . . . . . . . . . . 48

Disengaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 47

Display Units, Standard/Metric. . . . . . . . . . . . . . . 31

Drive Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . . 101

Drivetrain Break-In . . . . . . . . . . . . . . . . . . . . . . . . 34

Driving Downhill. . . . . . . . . . . . . . . . . . . . . . . . . . 41

Driving in Reverse. . . . . . . . . . . . . . . . . . . . . . . . . 43

Driving on a Sidehill . . . . . . . . . . . . . . . . . . . . . . . 41

Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 39

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . . 40

Driving Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 37

Driving Through Water . . . . . . . . . . . . . . . . . . . . . 42

Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Driving with a Passenger. . . . . . . . . . . . . . . . . . . . 38

Driving, After Driving in Water . . . . . . . . . . . . . . 75

Drying the Transmission . . . . . . . . . . . . . . . . . . . . 75

Dumping the Cargo Box . . . . . . . . . . . . . . . . . . . . 46

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-89

Charging (Conventional) . . . . . . . . . . 89

Charging (Sealed) . . . . . . . . . . . . . . . . 89

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Installation . . . . . . . . . . . . . . . . . . . . . 88

Removal . . . . . . . . . . . . . . . . . . . . . . . 87

Storage . . . . . . . . . . . . . . . . . . . . . . . . 88

Battery Warnings. . . . . . . . . . . . . . . . . . . . . . . . . 86

Beam Adjustment, Headlight. . . . . . . . . . . . . . . . 84

Belt Burning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Belt Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 75

Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 79

Brake Light Inspection . . . . . . . . . . . . . . . . . . . . 83

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Brake, Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Brake, Park, Adjustment . . . . . . . . . . . . . . . . . . . 80

Brake, Park, Inspection . . . . . . . . . . . . . . . . . . . . 79

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-80

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Electromagnetic Interference. . . . . . . . . . . . . . . . . 58

Electronic Power Steering . . . . . . . . . . . . . . . . . . . 24

Emission Control, Crankcase . . . . . . . . . . . . . . . . 58

Emission Control, Exhaust . . . . . . . . . . . . . . . . . . 58

Emission Control, Noise . . . . . . . . . . . . . . . . . . . . 58

Emissions Limited Warranty. . . . . . . . . . . . 107-108

Engaging AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Engine Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Engine Fogging . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . 78

Engine Intake Restrictor Plate. . . . . . . . . . . . . . . . 63

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Engine Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 36

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Equipment Modifications . . . . . . . . . . . . . . . . . . . 15

Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 33

Exhaust Emission Control System . . . . . . . . . . . . 58

Exhaust System Warning . . . . . . . . . . . . . . . . . . . 77

Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cab Frame, ROPS . . . . . . . . . . . . . . . . . . . . . . . . 28

Cab Nets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Cargo Box, Dumping. . . . . . . . . . . . . . . . . . . . . . 46

Chart

Gearcase Specifications . . . . . . . . . . . 65

Periodic Maintenance . . . . . . . . . . 59-61

Check Engine Indicator . . . . . . . . . . . . . . . . . . . . 33

Cleaning and Storage. . . . . . . . . . . . . . . . . . . . 90-92

Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching, 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Clutching, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Clutching, Crew. . . . . . . . . . . . . . . . . . . . . . . . . . 99

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Fan, Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Filter Cleaning, Air. . . . . . . . . . . . . . . . . . . . . . . . 76

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Fluid, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fluid Change

Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Inspection, Pre-Ride . . . . . . . . . . . . . . . . . . . . . . . 35

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 29-33

Intake Restrictor Plate. . . . . . . . . . . . . . . . . . . . . . 63

Interference, Electromagnetic. . . . . . . . . . . . . . . . 58

Engine Oil . . . . . . . . . . . . . . . . . . . . . . 64

Front Gearcase . . . . . . . . . . . . . . . . . . . 68

Main Gearcase (4X4/Crew) . . . . . . . . . 66

Main Gearcase (6X6). . . . . . . . . . . . . . 67

Middle Gearcase . . . . . . . . . . . . . . . . . 69

Rear Gearcase . . . . . . . . . . . . . . . . . . . 70

Transmission (4X4/Crew) . . . . . . . . . . 66

Transmission (6X6) . . . . . . . . . . . . . . . 67

Fluid Level

Engine Oil . . . . . . . . . . . . . . . . . . . . . . 63

Front Gearcase . . . . . . . . . . . . . . . . . . . 68

Main Gearcase (4X4/Crew) . . . . . . . . . 66

Main Gearcase (6X6). . . . . . . . . . . . . . 67

Middle Gearcase . . . . . . . . . . . . . . . . . 69

Rear Gearcase . . . . . . . . . . . . . . . . . . . 70

Transmission (4X4/Crew) . . . . . . . . . . 66

Transmission (6X6) . . . . . . . . . . . . . . . 67

Fluid Levels During Storage. . . . . . . . . . . . . . . . . 92

Fluid Part Numbers. . . . . . . . . . . . . . . . . . . . . . . 100

Fogging the Engine. . . . . . . . . . . . . . . . . . . . . . . . 92

Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fuel Tank Filler Cap. . . . . . . . . . . . . . . . . . . . . . . 24

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Key, Periodic Maintenance Chart. . . . . . . . . . . . . 59

Lamp Replacement, Headlight . . . . . . . . . . . . . . . 83

Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-84

Load Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Lubrication Recommendations. . . . . . . . . . . . . . . 62

Main Gearcase (6X6) . . . . . . . . . . . . . . . . . . . . . . 67

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . 109

Maintenance, Periodic . . . . . . . . . . . . . . . . . . 59-61

Metric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Middle Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Modifications to Vehicle . . . . . . . . . . . . . . . . . . . 15

Noise Emission Control System. . . . . . . . . . . . . . 58

Obstacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Oil

Engine . . . . . . . . . . . . . . . . . . . . . . 63-64

Transmission (4X4/Crew) . . . . . . . . . . 66

Oil and Filter Care During Storage. . . . . . . . . . . . 91

Oil Change

Engine . . . . . . . . . . . . . . . . . . . . . . . . . 64

Front Gearcase . . . . . . . . . . . . . . . . . . . 68

Main Gearcase (4X4/Crew) . . . . . . . . . 66

Main Gearcase (6X6). . . . . . . . . . . . . . 67

Middle Gearcase . . . . . . . . . . . . . . . . . 69

Rear Gearcase . . . . . . . . . . . . . . . . . . . 70

Transmission (4X4/Crew) . . . . . . . . . . 66

Transmission (6X6) . . . . . . . . . . . . . . . 67

Oil Level

Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Gasoline Handling . . . . . . . . . . . . . . . . . . . . . . . . 18

Gear Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Gearcase Specification Chart . . . . . . . . . . . . . . . . 65

Gearcase, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Gearcase, Middle . . . . . . . . . . . . . . . . . . . . . . . . . 69

Gearcase, Rear (6X6) . . . . . . . . . . . . . . . . . . . . . . 70

Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-70

Gears, Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine . . . . . . . . . . . . . . . . . . . . . . . . . 63

Front Gearcase . . . . . . . . . . . . . . . . . . . 68

Main Gearcase (4X4/Crew) . . . . . . . . . 66

Main Gearcase (6X6). . . . . . . . . . . . . . 67

Middle Gearcase . . . . . . . . . . . . . . . . . 69

Rear Gearcase . . . . . . . . . . . . . . . . . . . 70

Transmission (4X4/Crew) . . . . . . . . . . 66

Transmission (6X6) . . . . . . . . . . . . . . . 67

Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Headlight Beam Adjustment. . . . . . . . . . . . . . . . . 84

Headlight Lamp Replacement . . . . . . . . . . . . . . . 83

Helmet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Hitch Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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INDEX

Oil Recommendation, Engine . . . . . . . . . . . . . . . 63

Operation on Public Lands . . . . . . . . . . . . . . . . . 58

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 13-20

Outlets, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety, Winch Maintenance. . . . . . . . . . . . . . . . . . 57

Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Severe Use Definition . . . . . . . . . . . . . . . . . . . . . . 59

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Shock Loading the Winch . . . . . . . . . . . . . . . . . . . 56

Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 80

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Spark Arrester Warning. . . . . . . . . . . . . . . . . . . . . 77

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 71

Spark Plug Recommendations. . . . . . . . . . . . . . . . 71

Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . 71

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Spark Plugs, Fouled. . . . . . . . . . . . . . . . . . . . . . . . 71

Specifications, 4X4 . . . . . . . . . . . . . . . . . . . . . 94-95

Specifications, 6X6 . . . . . . . . . . . . . . . . . . . . . 96-97

Specifications, Crew . . . . . . . . . . . . . . . . . . . . 98-99

Specifications, Gearcase . . . . . . . . . . . . . . . . . . . . 65

Speed, Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Spring, Shock, Adjustment . . . . . . . . . . . . . . . . . . 80

Stabilizing the Fuel . . . . . . . . . . . . . . . . . . . . . . . . 91

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . 36

Steering Wheel Inspection. . . . . . . . . . . . . . . . . . . 80

Steering Wheel, Adjustment . . . . . . . . . . . . . . . . . 24

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . 36

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-92

Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Storage Compartments . . . . . . . . . . . . . . . . . . . . . 28

Storage, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Storage, Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Storage, Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . 92

Storage, Oil and Filter . . . . . . . . . . . . . . . . . . . . . . 91

Storage, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 93

Suspension Adjustment, Rear . . . . . . . . . . . . . . . . 80

Switches

Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Park Brake Adjustment . . . . . . . . . . . . . . . . . . . . 80

Park Brake Inspection . . . . . . . . . . . . . . . . . . . . . 79

Parking on an Incline. . . . . . . . . . . . . . . . . . . . . . 43

Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 43

Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Periodic Maintenance Chart . . . . . . . . . . . . . . 59-61

Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Plug, Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Plugs, Spark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . 100

Polishing the Vehicle. . . . . . . . . . . . . . . . . . . . . . 90

Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Steering Unit (Cleaning). . . . . . . . . . . . . . 82

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 35

Product Part Numbers . . . . . . . . . . . . . . . . . . . . 100

Public Lands . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

PVT Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

PVT System. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-75

PVT Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 74-75

PVT, Cleaning Debris . . . . . . . . . . . . . . . . . . . . . 75

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . 73

Rear Gearcase (6X6) . . . . . . . . . . . . . . . . . . . . . . 70

Rear Suspension Adjustment. . . . . . . . . . . . . . . . 80

Receiver Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Removing the Vehicle from Storage . . . . . . . . . . 93

Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . 43

Rider Information Center. . . . . . . . . . . . . . . . . 30-33

Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Rollover Protective Structure . . . . . . . . . . . . . . . 28

ROPS Cab Frame. . . . . . . . . . . . . . . . . . . . . . . . . 28

AWD Switch. . . . . . . . . . . . . . . . . . . . 23

Differential Lock Switch . . . . . . . . . . 23

Ignition . . . . . . . . . . . . . . . . . . . . . . . . 23

Light . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Mode Button . . . . . . . . . . . . . . . . . . . . 23

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INDEX

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Throttle Freeplay Adjustment. . . . . . . . . . . . . . . . 78

Throttle Freeplay Inspection. . . . . . . . . . . . . . . . . 78

Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Throttle System. . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Tire Tread Depth. . . . . . . . . . . . . . . . . . . . . . . . . . 81

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-82

Torque, Axle Nuts. . . . . . . . . . . . . . . . . . . . . . . . . 81

Torque, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 71

Torque, Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . 81

Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Towing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Transmission (4X4/Crew). . . . . . . . . . . . . . . . . . . 66

Transmission (6X6) . . . . . . . . . . . . . . . . . . . . . . . 67

Transmission Operation . . . . . . . . . . . . . . . . . 74-75

Transmission System . . . . . . . . . . . . . . . . . . . 74-75

Transmission Warning . . . . . . . . . . . . . . . . . . 74-75

Transmission, Drying . . . . . . . . . . . . . . . . . . . . . . 75

Transporting the Vehicle . . . . . . . . . . . . . . . . . . . 93

Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Vehicle Identification Numbers . . . . . . . . . . . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . . . 76

Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . 93

Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning, Transmission Modification. . . . . . . 74-75

Washing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 90

Water, Immersion of Vehicle . . . . . . . . . . . . . . . . 76

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 82

Wheel Nut Inspection . . . . . . . . . . . . . . . . . . . . . . 81

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 81

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Winch Cable Care. . . . . . . . . . . . . . . . . . . . . . . . . 55

Winch Maintenance and Service Safety. . . . . . . . 57

Winch Operation. . . . . . . . . . . . . . . . . . . . . . . 51-54

Winch Safety Precautions. . . . . . . . . . . . . . . . 49-50

Winch Shock Loading . . . . . . . . . . . . . . . . . . . . . 56

113

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