Polaris 500 2X4 manual

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The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm. W ARNING[...]

1 WELC OME Thank you for purcha sing a Polar is vehicle , and welc ome to our world-w ide family of Polar is owners. W e proudly produce a n exciting line of utility a nd re cr ea tional produc ts. S Snowmobiles S All-te rr ain ve hicle s (A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Polaris sets a standa rd of exc elle[...]

2 Copyri ght 2005 Pola r is Sa l es I nc . A ll inf or ma t ion c ont a ine d wi t hin t hi s publ i ca tion i s bas e d on the l a te st produc t inf or ma t ion at t he t ime of publ i c at i on. Due to cons tant imp ro vem ents in the desig n an d q uality o f pr oduct ion com ponent s , som e mi nor discrep an cies may result betw een th e actu[...]

3 TABLE OF CONTENTS VEHICLE IDENT IF ICA TIO N NUMBERS 4 ........ SAFET Y 5 ................................... FEA TURES AND CONTROLS 23 ............... OPER A TION 32 .............................. EMISSI ON CONT ROL SYSTEM S 51 ............ MAINTENANCE AND LUBRICA TION 53 ......... POLARIS PRODUCTS 101 ..................... SPECIF ICA TIO NS 10 [...]

4 VEHICLE IDE NTIFICATION NUMBERS Recor d your vehic le’ s identification numbe rs a nd key number in the spaces p rovi ded . Rem ove t he s pare k ey and s tor e it i n a s afe place. Y our key can be duplica ted only by mating a Polaris ke y blank with one of your existing ke ys, so if both keys ar e lost, the ignition switc h mus t be rep lace[...]

5 SAFE TY Operator S afety W ARNING Failur e to f ollow the war nings cont ained in t his manual c an result in severe injur y or deat h. A Polaris RA NGER is not a t oy and c an be hazardous t o operat e. This vehic le handles differ ently t han other v ehicles, s uch as motorcycles and cars. A collision o r rollover c an occur quickly , even duri[...]

6 SAFE TY Operator S afety The following signa l words and symbols a ppea r throughout this manual a nd on your RANGER . Y our sa fety is involve d when the se words a nd symbols are used. Beco me familia r with their mea nings befor e re ading the manual. The safety aler t sy mbol , on y our vehic le or in t his manual, aler ts you to t he pot ent[...]

7 SAFE TY Operator S afety W ARNING Serious injury or deat h can res ult if y ou do not f ollow t hese instr uct ions and proc edures, which are out lined in f urt her det ail within your owner ’s manual. S Rea d this manual a nd all labe ls car ef ully . Follow the opera ting pro- cedur es desc ribed. S Never a llow anyone without a valid driver[...]

8 SAFE TY Operator S afety S Always follow pr oper pr ocedur es for turning as desc ribed in this manual. Pra ctice t urning at slow spe eds be for e atte mpting to turn at faste r spee ds. Never turn a t excessive spe eds. S Always h ave th is v ehi cle checked b y an aut hor ized P ol aris d ealer i f it has been i nvolved i n an accident. S Neve[...]

9 SAFE TY Operator S afety S Never modify this vehic le through imprope r installa tion or use of accesso ries . S Never exceed the stated load capaci ty for thi s vehicl e. C argo should be prop erly d is tri bu ted an d secu rely at tach ed. R educe sp eed and follow the instr uctions in this ma nual for hauling ca r go or pulling a trai ler . Al[...]

10 SAFE TY Operator S afety W ARNING Make sure yo ur RANG ER is in ex cellent oper ating c ondition at all tim es. We str ongly rec ommend t hat t he operat or chec k all saf et y component s bef ore eac h ride. Pola ris RANGE R s are des igned to pr ovide saf e operat ion when used as dir ect ed. F ailure of c rit ical mac hine component s m ay re[...]

11 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Stalling, rolling backw ards while climbing a hill WHA T CA N HAPPEN V ehicle overt urn HOW TO A VOID THE HAZ ARD Maint ain a steady s peed when climbing a hill. I fy o ul o s ea l lf o r w a r d s peed: Apply t he brakes . Lock t he park ing brake af ter f ully s topped. If y ou begin rolling[...]

12 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his vehic le on paved sur fac es WHA T CA N HAPPEN Loss of c ontrol HOW TO A VOID THE HAZ ARD This vehic le’s tires ar e designed f or off- road use only , not f or us e on pavement . Paved sur fac es may s eriously affec t handling and cont rol of t he vehicle, and may caus e t[...]

13 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his vehic le on public st reet s, roads or highways WHA T CA N HAPPEN Collision with anot her v ehicle HOW TO A VOID THE HAZ ARD Never oper ate t his vehic le on any public st reet , road or highway , including dirt or gr avel. In many s tat es it ’s illegal to operat e vehic le[...]

14 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his vehic le at ex cess ive speeds WHA T CA N HAPPEN Loss of cont rol, acc ident HOW TO A VOID THE HAZ ARD Always t rav el at a s peed proper f or t he t errain, visibilit y and operat ing conditi ons, and y our exper ience. W ARNING POTENTI AL HAZA RD Att empt ing jum ps and othe[...]

15 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failur e to inspec t t he vehic le befor e operat ing Failure t o proper ly maint ain t he vehicle WHA T CA N HAPPEN Acc ident, equipm ent damage HOW TO A VOID THE HAZ ARD Always inspec t your RA NGE R befor e each use t o mak e sure it ’s in safe oper ating c ondition. Always f ollow the in[...]

16 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failur e to f ollow the m inimum age r ecomm endations f or t his vehi cle WHA T CA N HAPPEN Serious injury or deat h (t he child or ot hers ) HOW TO A VOID THE HAZ ARD Only per sons wit h a valid dr iver ’s license should operat e a Polar is RANGE R . Even t hough a child may be wit hin t h[...]

17 SAFE TY Operator S afety W ARNING Leaving the k eys in t he ignit ion can lead t o unauthor ized use of the vehic le result ing in ser ious injury or deat h. Always r emove the ignit ion key when t he vehicle is not in us e. W ARNING Aft er any ov ert urn or ac cident , hav e a qualified s ervic e dealer inspect t he ent ire vehic le for poss ib[...]

18 SAFE TY Safety D ecals and Locations W arni ng d ecals h ave been p laced o n th e RANGER for your pr otection. Read an d fol lo w the in st ruct io ns o f the decal s on t he RANGER carefull y . If any o f th e decals d epi cted i n t hi s m anual d iffer from t he decals o n your RANGER , always r ead a nd follow the instructions of the decal [...]

19 SAFE TY Safety D ecals and Locations Fuel / Passenger W arning Decal T ext Remove fla mmable conta iner s from box before r efue ling. S Passenger s ca n be thrown of f. This can cause serious injury or death. S Never carr y passenge rs in ca r go box. Maximum 2X4 (TM) Box Load 750 lbs. (340 kg) Maximum 4X4 Box Load 1000 lbs. (454 kg) 1 2 3 4 Re[...]

20 SAFE TY Safety D ecals and Locations MANUFACTURED BY: PO LAR IS IND IN C. DA TE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHIC LE AND IS NO T INTEND ED FOR USE ON PUBLIC ROADS. 7078472 CE VÉH IC UL E U SAGE GEN ER AL VEH IC UL E U TILIT - AI RE P OUR SERV I CE HORS ROUTE QUI NE ST P A S DES - TINE A ETRE UTILISE SUR L ES CH EMIN[...]

21 SAFE TY Safety D ecals and Locations Discretionar y W arning Decal Improper ve hicle use c an result in SEVERE INJUR Y or DEA TH. NEVE R: S Oper ate on public ro ads. A collision c an oc cur with anothe r ve hicle . S Carry mor e than two pa ssenge rs, or passe ngers unde r age five. S Use ALCOHOL or DRUGS before or whi le operat ing t his vehic[...]

22 SAFE TY Fuel Safety W ARNING Gasoline is highly f lammable and is ex plosive under cer tain conditi ons. Always ex ercis e ext reme c aution whenev er handling gasoline. Always s top t he engine when ref ueling. Always ref uel out doors or in a well v entilat ed area. Do not sm oke or allow open f lames or s parks in or near t he ref ueling area[...]

23 FEATURES AND CONTROLS So me P olari s veh icl es are equi pped wi t h speci al feat ures s uch as th e cab frame. Not all models c ome with all featur es. Ref er t o the specif ications se ction beg inning on page 102. Com ponent Locations 1. Cab Frame (if equippe d) 2. Hip Bar 3. Console 4. S t eerin g Wheel 5. S eat 6. Car go Box 7. S eat B el[...]

24 FEATURES AND CONTROLS Com ponent Locations 10. Headlights 1 1. Radia tor (if equippe d) 12. Front Bumper/Brush Guard 13. Hood Hold Down S trap 12 11 10 13[...]

25 FEATURES AND CONTROLS Com ponent Locations 14. T aillights 15. T ailga te 16. T ail gat e Lat ch R eleas e 17. Muf fler ( Spark Ar re ster) 18. CV Boot/Rear Ca liper 19. Air Box 20. Recei ver Hi t ch 14 14 20 17 16 18 18 19 15[...]

26 FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display: 1. High Gear 2. Low Gear ( if equipped) 3. Neutral G ear 4. Reverse Ge ar 5. High T empe rature 6. B rakes T railer Hitch Br acket Thi s v ehi cle i s eq ui pped wi th a recei ver h it ch b racket fo r a trai l er hi tch. T railer towing equipment is not supplied[...]

27 FEATURES AND CONTROLS Seat Rem oval Pull up on the front of the seat and slide it t oward the front of the vehic le. Install the se at by sliding the tabs into the rea r of the seat base. Push down firmly on the front of the sea t until the p ins are fully seate d into the grommets. Seat Belts The RANGER is equipped with lap-style se at belts fo[...]

28 FEATURES AND CONTROLS Console 1. Cup Holder 2. Indica tor Lights 3. S h ift L ever 4. Light Switch 5. A WD/Dif fe re ntial Switch (if equippe d) 6. Hour Meter 7. Glove Box with Lid 8. 12V Acce ssory Plug 9. Storage T ray 10. Choke Knob 1 1. Ignition Switc h 12. Dif fer ential Lock Le ver ( if equipped) 13. Storage Box 11 10 6 2 8 12 3 7 13 1 4 5[...]

H L N R H N R 29 FEATURES AND CONTROLS Gear Selector (1) RANGER 2X4, 4X4 H: High Gear L: Low Gear N: Neutral R: Rev er se RANGER TM H: High Gear N: Neutral R: Rev er se NOT E: Low is t he prim ary dr iving range f or t he RANGE R 2X4 and 4X4. High is int ended for us e on hard-pac ked sur fac es wit h light loads. T o change ge ar s, stop the vehic[...]

1 2 AW D D E F 2WD A B C 4 3 30 FEATURES AND CONTROLS Ignition S witch (1) The ignition switch is a three- position, key-oper ate d switch. The key can be remove d from the switc h when it is in the OFF position. OFF The engine is off. Elect ric al circ uits are off, ex cept Acc. 12V . ON Elect ric al circ uits are on. Elect rical equipm ent c an b[...]

1 2 3 4 31 FEATURES AND CONTROLS Br ake Pedal (1) Depre ss the brake ped al to slow or stop the vehicle . Throttle P edal (2) Pu sh t he pedal down t o i ncrease engine spee d. Spring pressure retur ns the pedal to t he rest position when r ele ased . Always che ck that the throttle peda l retur ns normally bef ore sta rting the engine. Make sure t[...]

32 OPERATION V ehicle Br eak -In Period The bre ak- in period for your new Pola ris RANGER is the first twenty hours of opera tion, or the time it takes to use the first two tanks full of gasoline. No single action on your pa rt is as impor tant as a pr oper brea k-in pe riod. Care ful tre atme nt of a new e ngine will r esult in mor e ef ficient p[...]

33 OPERATION Pr e -Ride Inspection W ARNING If a pr oper inspec tion is not done bef ore eac h use, sev ere injury or deat h could res ult. Always ins pect t he vehicle bef ore eac h use to ens ure it ’s in proper operat ing condit ion. Pre - Ride Check li st Item Remarks See Page Brake system / lever t r avel Ensure proper oper at ion 86 Bra ke [...]

1 2 3 4 34 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains pois onous car bon monoxide and c an cause los s of cons ciousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. CAUTION Oper ating t he vehicle im mediat ely af ter s tar ting c ould cause engine damage. Allow the engine t o warm up[...]

35 OPERATION Star ting the E ngine Sta rti ng a W ar m E ngine W arm engine s do not normally requir e the use of the choke. Over use of the choke ca n cause the spa rk plug to become wet fouled . 1. Place the tra nsmission in neutra l and move the vehicle to a leve l surface. 2. Lock the pa rking bra ke. 3. S i t i n th e driv er ’ s s eat an d [...]

36 OPERATION Br aking 1. Rele ase the throttle pe dal comple tely . 2. P res s on t he brak e pedal ev enl y and fi rml y . NOT E: Pr act ice st art ing and st opping (us ing the br akes) unt il you’r e familiar wit h t he cont rols. NOT E: W hen the t hrot t le pedal is releas ed complet ely and t he engine speed drops near an idle, the vehic le[...]

37 OPERATION Driving Safely Driving Pr ocedures 1. S i t i n th e driv er ’ s s eat an d fast en th e seat bel t . 2. Afte r star ting the e ngine and a llowing it to wa rm up, shift the tran smission into gea r . 3. Check your surroundings and de termine your path of trave l. 4. Relea se the parking brake . 5. Keep in g bot h hand s on t he st e[...]

38 OPERATION Driving Safely Driving On S lippery Surfaces When dri vi ng o n sl ipp ery su rfaces such as wet t rai ls , l oos e gravel , o r ice, be a lert f or the possibility of skidding and sliding. Under the se cond it i ons , fo ll ow t hes e precau ti on s: 1. Slow down when ente ring slipper y are as. 2. M ain tai n a hig h lev el of al ert[...]

39 OPERATION Driving Safely Driving Uphill Whe neve r tra veling uphill, follow these pr ecauti ons : 1. Alwa ys trav el stra ight uphill. 2. A void ste ep hills (15 _ ma ximum). 3. Keep both f eet on the floor . 4. P ro ceed at a st eady rat e of speed an d th ro ttle opening. W ARNING Climbing hills im properly can c ause loss of c ontr ol or veh[...]

40 OPERATION Driving Safely Sidehilling W ARNING Cross ing hillsides or t urning on hills c an result in los s of c ontrol or vehicle ov ert urn, res ulting in s evere injur y or deat h. Avoid cros sing t he side of a hill when poss ible. W hen unavoidable, exerc ise ext rem e caut ion. Avoid operat ing on st eep hills ( 15 _ maximu m). Driving Dow[...]

1 41 OPERATION Driving Safely Dr ivi ng Through W ater W ARNING The lar ge tir es on your RANG ER m ay caus e the v ehicle t o float in deep or f ast- flowing wat er, which could res ult in los s of cont rol and lead to ser ious injur y or deat h. Never cr oss deep or fast -f lowing wat er wit h your RA NGE R . Y our P olaris RANGER can opera te th[...]

42 OPERATION Driving Safely Driving Over Obstacles Be alert ! Lo ok ah ead and learn t o read t he terrai n yo u’re trav eli ng on . W at ch for hazard s such as l og s, rocks an d lo w hang in g bran ches. W ARNING Sever e injury or deat h can res ult if y our vehic le suddenly c omes in contac t wit h a hidden obst acle. Not all obst acles ar e[...]

43 OPERATION Driving Safely Driving in Rever se Follow these guide lines when ope ra ting in reve rse: 1. Back slowly . 2. Apply the bra kes lightly for stopping. 3. A void turning at sha rp angle s. 4. Always a void bac king downhill. 5. Neve r open the throttle suddenly while ba cking. 6. Always inspec t lef t and r ight fields of vision before b[...]

44 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void par king on an inc line if possible . If it’ s unavoidable, follow thes e precau ti on s: 1. Place the tra nsmission in gear . 2. Set the parking brake. 3. Block the rear whee ls on t he downhill side. W ARNING A rolling v ehicle can c ause proper ty damage and s erious injur y .[...]

45 OPERATION Hauling Cargo W ARNING Hauling cargo im properly can alt er v ehicle handling and may cause los s of c ontr ol or brak e inst ability , which can r esult in serious injur y or death. Always f ollow thes e precaut ions when hauling cargo: Always load t he car go box wit h the load as f ar f orwar d as possible. Always oper ate t he vehi[...]

46 OPERATION Hauling Cargo Dumpin g the Cargo Bo x W ARNING Operat ing t he vehicle while t he car go box is r aised could r esult in sever e injury . T he box c ould close unex pect edly and caus e injury to t he driver or pas senger . T he rear t ires will als o cat ch t he rear of a r aised box, dam aging the v ehicle and cr eating haz ardous dr[...]

47 OPERATION Hauling Cargo T owing Loads W ARNING T owing improper ly can alt er v ehicle handling and may c ause loss of cont rol or br ake inst abilit y , whic h can res ult in s erious injur y or death. Always f ollow t hese prec autions when t owing: Never load m ore t han 150 lbs. (68. 1 kg) t ongue weight on t he tow in g b rac ke t. Do not o[...]

48 OPERATION Driving Safely Park in g t h e RANGER W ARNING A rolling v ehicle can c ause proper ty damage and s erious injur y . Always apply t he park ing brake af t er st opping t he engine. 1. S t op t he v ehi cle o n a l evel s urface. 2. When the engine ha s stopped, apply the parking brake. 3. Remove the i gnition switch ke y to pre vent un[...]

AW D 2WD AW D 2WD 49 OPERATION Differ ential Operati on Modes The re ar a xle is equipped with a locka ble dif fe re ntial. On A WD models, engaging A WD locks the front dif fe ren tial and the rea r dif fe re ntia l. CAUTION Damage to t he differ ential c an occur if it is engaged while the vehicle is t raveling at high s peeds or while t he rear [...]

50 OPERATION All Wheel Drive ( A WD) Whe n in A WD, the front gearc ase w ill automatic ally enga ge anytime the r ear wheel s l ose t ract ion . When t he rear wh eels reg ain t racti on , t he front ge ar ca se will a utomatic ally disengage . The re is no limit to the length of time the vehic le may r ema in in A WD . Engaging Front Gearcase The[...]

51 EMISSION C ONT RO L SYST EMS Cr ankcase Em ission Contr ol S ystem This engine is equipped with a closed c rankc ase syste m. Blow-by gases a re forc ed ba ck to the c ombustion cha mber by the intake system. All exhaust g ases e xit through the exhaust system. Exhaust E m ission Contr ol S ystem The emissions from the exha ust of this vehicle a[...]

52 EMISSION C ONT RO L SYST EMS Noise Em ission C ontrol System Do not modify the engine, intake o r exhaust compone nts, as doing so may af fect complianc e with U.S. A. EP A noise control re quireme nts (40 CFR 205) and loca l noise le vel r equire ments. Operation on Public Land s in the U.S.A. Y our Polaris vehic le ha s a spa rk ar re stor tha[...]

53 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Care ful periodic ma intenanc e will help keep your vehic le in the safest, most relia ble c ondition. Inspection, ad justment and lubr ica tion of important compone nts are e xplained in the periodic mainte nanc e char t. Insp ect, cl ean, l ub ricat e, adj us t and replace parts as neces[...]

54 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Maintenanc e Char t Ke y " Perfo rm t hese p roced ures m ore freq uent ly fo r vehi cles s ubj ect ed to sever e use. E Emission-re late d servic e (Failur e to conduct this maintenan ce will not void the emissions warra nt y but may af fect emissions.) J Have an au th ori zed P ol a[...]

55 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all s ervices at wh ich ever main ten ance int erval i s reached firs t. Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Steering -- P re-R ide -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us pe[...]

56 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) " E Engine breather filter (if equipped) 25 H Monthly -- Inspec t; r eplace if nec es s ary " Engine oil c hange (brea k-in) 25 H 1M -- Perform a break -in oil change at one month " Ge[...]

57 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J E Fu e l syste m 100 H 12 M -- C hec k for leaks at tank cap, lines, fuel v alv e, filter, pump, car buretor ; replac e lines ever y t wo y ears J E Fuel filter 100 H 12 M -- Replac e y early "[...]

58 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations Chec k and lubric ate all compone nts at the inte rva ls outlined in the Periodic Mainte nanc e Chart beginning on page 53. Items not listed i n the char t should be lubricated at the Ge nera l Lubrication inter val. Lubri cati on Char t K ey " More of ten under sever e use , such a[...]

59 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations (1) (2) TM 4X4 TM[...]

60 MAINTENANCE AND LUBRICATION Engi ne Oil Always che ck an d change the engine oil at the interv als outlined in the Peri od ic M ain ten ance C hart beg i nning on page 53. Always change the oil filter whe neve r changing oil. Pr emium 4 S ynthetic Oil Polaris Pre mium 4 All Season Synthetic e ngine oil ha s been spe cia lly formula ted for use i[...]

1 61 MAINTENANCE AND LUBRICATION Engi ne Oil Alwa ys chec k and c hange the oil at the inte rva ls outlined in the Periodic Mainte nanc e Chart beginning on page 53. W e recomme nd the use of Polaris Premium 4 All S eason Synthetic e ngine oil. Oil Check (2x4, 4X4) The oil tank is loc ated unde r the seat . 1. Position the vehicle on a level s urfa[...]

62 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Change (2x4, 4X4) CAUTION Hot oil c an cause s erious bur ns. Do not allow hot oil t o com e into contac t wit h sk in. 1. Run the engine two to three minutes until warm. Stop the engine. 2. Clean the ar ea ar ound the drain plug (1) at the bottom of the oil tank. 3. P l ace a drain pan b en[...]

5 63 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Change (2x4, 4X4) 8. Rea ttac h the oil line. 9. Place shop towe ls benea th the oil filter (5). Using an oil filter wre nch, turn the filter counter clockwise to remove . 10. Usin g a clean dry cl ot h, cl ean the filter se aling surf ac e on the crankcas e. 1 1. Lubrica te the gasket on [...]

64 MAINTENANCE AND LUBRICATION Engi ne Oil Oil Pump Pr im ing (2x4, 4X4) This priming proce dure must be perform ed when ever t he oi l ho se conne ction be twee n the oil tank and pump inlet ha s been disconnec ted. 1. Clamp or pinch off the ve nt line (1) appr oximate ly 2 I from th e oil t ank (2), between the end of the oil tank vent fitting an[...]

65 MAINTENANCE AND LUBRICATION Engi ne Oil Oil Check (TM) 1. Position the vehicle on a leve l surface. 2. Start the engine and let it idle for 20-30 sec onds. 3. Stop the engine and remove the seat as d escri bed on p age 27. Remove the servic e pane l (1) by pulling upwar d. 4. Remove the dipstic k (2) and wipe it dry with a c lea n cloth. 5. Repl[...]

66 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Change (TM) 1. Position the vehicle on a leve l surf ace. 2. Run the engine two to three minutes until warm, then stop the engine . 3. Clean the are a ar ound the drain plug (6) at the bottom of t he engine. The pl ug is accessi ble t hr ough the access hol e i n the bottom of the skid plate[...]

67 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Change (TM) 7. Place shop towels benea th the oil filter (1). Using an oil filte r wre nc h (2) , turn the filte r counter clockwise to remove . 8. Using a c lean dr y cloth, cle an the filter sea ling surfa ce on the crankcas e. 9. C heck t o mak e sure t he o -rin g (3) is in good conditio[...]

68 MAINTENANCE AND LUBRICATION Gearcases Gearcase S pecification Chart Gear case Lubricant Capacit y Fill Plug T or que Drain Pl ug T or que Ma i n Ge a rca se (Transmis s ion) (4X4) Premi um AGL Sy nthetic G earc as e Lube 15.2 oz. (450 ml) 14 ft. lbs . (19.4 N m) 14 ft. lbs . (19.4 N m) Ma i n Ge a rca se (Transmis s ion) (2X4, TM ) Premi um AGL [...]

69 MAINTENANCE AND LUBRICATION Gearcases T ransmission (Main Gear case) Always che ck an d change the tra nsmission oil at the interva ls outlined in the Periodic Mainte nanc e Chart beginning on page 53. Maintain the oil level e ven with the bottom of the fill plug hole. W e rec ommend the use of Premium AGL Synthetic Gearc ase Lubr icant. S ee pa[...]

70 MAINTENANCE AND LUBRICATION Gearcases Front Gearcase (4X4) Always ch eck and ch ange t he fro nt gearcas e oi l at t he i nt erval s outlined in the Periodic Mainte nanc e Chart beginning on page 53. Mainta in the oil leve l even w ith the bottom thre ad of the fill plug hole. W e rec omme nd the use of Polaris Premium Dema nd Drive Hub Fluid. S[...]

1 2 1 2 TM 2X4 4X4 71 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always che ck an d change the re ar ge arc ase oil at the interva ls outlined in the Periodic Mainte nanc e Chart beginning on page 53. Maintain the oil level e ven with the bottom thre ad of the fill plug hole . W e rec ommend the use of Polaris A TV Angle Drive Fluid. S ee [...]

72 MAINTENANCE AND LUBRICATION Cooling System (2X 4, 4X 4) Operation The engine coola nt level is controlled or mainta ined by the recove ry system. The rec overy syste m components are the ove rflow bottle, radia tor fille r nec k, radiator pr essur e ca p and conne cting hose. As coolant operating tempe ratur e incre ases, the expanding (he ated)[...]

73 MAINTENANCE AND LUBRICATION Cooling System (2X 4, 4X 4) Radi ator and Cool ing Fan Always ch eck and cl ean th e screen and radi at or fin s at th e int erval s outlined in the Periodic Mainte nanc e Chart beginning on page 53. Do not obstruct or defle ct air f low through the radia tor by installing unau th ori zed access ories i n fron t of t [...]

1 74 MAINTENANCE AND LUBRICATION Cooling System (2X 4, 4X 4) Radiator Coolant L evel Always c hec k and c hange the coola nt at the inte rvals outline d in the Periodic Maintena nce Cha rt beginning on page 53. W ARNING Esc aping steam c an cause s evere bur ns. Never r emove t he press ure cap while t he engine is warm or hot . A lways allow t he [...]

75 MAINTENANCE AND LUBRICATION Spar k Pl ugs CAUTION Using non-r ecomm ended spark plugs c an result in serious engine damage. Always us e Polaris -rec ommended s park plugs . Refer to t he specif icat ions s ect ion beginning on page 102. Spark P lug Ga p/T orque Model Elect r ode Gap New Pl ug T or que Used Plug T orque RANGER 2X4, 4X4 .025 ″ ([...]

76 MAINTENANCE AND LUBRICATION Polar is V ar iable T ransm ission (PV T) System W ARNING Failure t o com ply wit h the ins tr uct ions in t his warning can r esult in sever e injury or deat h. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength so t hat a f ailure m ay occ ur at a high speed. The PVT system has been[...]

77 MAINTENANCE AND LUBRICATION V eh i cl e Imme rsi o n CAUTION If y our vehic le becomes im mers ed, m ajor engine damage c an result if t he vehic le is not t horoughly inspec ted. T ak e the v ehicle to your dealer bef ore s tart ing t he engine. If it’ s impossible to take your RANGER to a dea ler be for e star ting it, follow the steps outli[...]

1 78 MAINTENANCE AND LUBRICATION Filter S ystems (2X 4, 4X4) Air Filter Alwa ys change the a ir filter a t the interva ls outlined in the P eriodic Maintena nce Char t beginning on page 53. 1. L ift t he cargo box t o access t he air box. 2. Remove the air box cove r and inspect the gasket. It should adher e tightly to the cover and seal a ll the w[...]

79 MAINTENANCE AND LUBRICATION Filter S ystems (2X 4, 4X4) Breather Filter and Hoses 1. Lift the ca r go box and loc ate the air box. 2. Follow the right-hand brea ther line (1) out the side of the air box and locate the filte r (2). 3. Remove a nd inspect the filter for deb ris. Blow gently through the filter in the dire ction of the arr ow to che[...]

80 MAINTENANCE AND LUBRICATION Filter S ystems (TM) Air Filter Always ch eck and ch ange t he ai r filter at the interva ls outlined in the Peri od ic M ain ten ance C hart beginning on page 53. 1. R em ove t he s eat t o access t he ai r clean er . 2. Remove the brea ther hose (1) f rom the cylinder . 3. Remove the wing nut (2) and remove th e air[...]

81 MAINTENANCE AND LUBRICATION Car bur etor/ Engi ne Idle R PM A djustm ent The idle spe ed a djustment should be pe rf ormed a s outlined in the Peri od ic M ain tenan ce C hart, or wh enever t he i dl e sp eed i s chan ged . Recomme nded engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. Recomme nded engine idle RPM for the RANGER TM is [...]

82 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following war nings while ser vicing t he spar k arres tor could r esult in ser ious injury or deat h. Do no t perform service on the sp ark arrestor whi le the system is hot. Exhaust system t em peratures ca n r each 1000 ° F . Allow component s t o cool suff icient ly[...]

83 MAINTENANCE AND LUBRICATION Spar k Ar restor Use th e fol lo wing p rocedu re to peri od ical ly pu rge accumul ated carbo n from the exhaust pipe . 1. Remove the ar restor clean-o ut p lu gs (1 ) lo cated on the bottom of the muf fle r . 2. Place the tra nsmission in neutra l and sta rt the e ngine. 3. P urge accum ul at ed carbo n from the sys[...]

1 2 84 MAINTENANCE AND LUBRICATION Throttle S ystem W ARNING Failur e to chec k or m aintain pr oper oper ation of t he t hrot tle system can r esult in an accident and lead t o serious injury or death if t he t hrot tle pedal s tic ks dur ing operat ion. Never s tar t or operat e t his vehic le if it has a s tic king or im properly operat ing thro[...]

85 MAINTENANCE AND LUBRICATION Throttle S ystem Throttl e Fre eplay I nspection 1. Apply the par king bra ke (2) and shift the tr ansmission to ne utral. 2. Start the e ngine and warm it up thoroughly . 3. Measur e the distance the thr ottle pedal moves befor e the engine begins to pick up spe ed. F ree play should be 1/16 to 1/8 inche s. Throttl e[...]

1 86 MAINTENANCE AND LUBRICATION Br akes The front and rea r brak es are hydra ulic disc type bra kes. Press down on the brake pe dal to engage the brake s. See page 31. Br ake Fl uid Routine inspections ar e rec ommende d to keep the brake syste m in good operating condition. Inspec t the level of the brake fluid bef ore each operat io n. Change t[...]

87 MAINTENANCE AND LUBRICATION Br akes Brake Inspection 1. Chec k the brake syste m for fluid leak s. 2. Check the bra ke pedal for exc essive trave l or a spongy feel. 3. C heck t he frict i on pad s for wear , damage a nd looseness. 4. Inspec t the brake disc spline a nd pad wear s urface for ex cess iv e wear . 5. Change pads whe n worn to 3/64 [...]

88 MAINTENANCE AND LUBRICATION Steer ing Wheel Inspection Ch eck the s teeri ng wh eel for sp ecifi ed freepl ay and sm oo th o perat io n at the interva ls outlined in the Periodic Mainten anc e Chart beg inning on page 53. 1. Position the vehicle on level ground. 2. Lightly turn the ste er ing whe el lef t and right. 3. There should be 0. 8 - 1.0[...]

89 MAINTENANCE AND LUBRICATION Seat Belts Insp ect al l t hree s eat bel ts fo r pro per op erati on befo re each u se of t he vehicle . 1. Push the latch plate into the buckle until it clicks. The latch pla te must slide smoothly into the buckle . A clic k indicate s that it’ s sec ure ly latche d. 2. Push the red button in the middle of the buc[...]

90 MAINTENANCE AND LUBRICATION Ti r e s W ARNING Operat ing your v ehicle wit h worn t ires will inc rease t he poss ibility of skidding, los s of contr ol and an accident , which could result in serious injur y or death. Always r eplace tir es when the tr ead depth m easures 1/ 8 ″ (.3 cm) or less. Im proper t ire inf lat ion or the us e of non-[...]

91 MAINTENANCE AND LUBRICATION Ti r e s W ARNING Im properly inst alled wheels c an advers ely affec t t ire wear and vehicle handling, whic h can res ult in s erious injur y or deat h. Always ens ure t hat all nut s ar e tor qued to s pecif icat ion. Do not serv ice axle nut s t hat hav e a cot ter pin ins talled. See your Polaris dealer. Wheel Re[...]

1 92 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a ha logen lamp, don’ t touch the la mp with bar e finger s. Oil from your skin leave s a r esidue, c ausing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driv ing can result in sever e injury or deat h. Headlight and t aillight lens es becom e dirt y dur[...]

1 93 MAINTENANCE AND LUBRICATION Lights Headlight Beam A djustment 1. P l ace th e vehi cle o n a l evel s urface wi th t he head li gh t approxima tely 25 f t. (7.6 m) from a w all. 2. Measur e the distanc e from the floor to the cente r of the headlight and m ake a m ark o n t he wall at t he s ame hei gh t. 3. Start the engine and switch on the [...]

94 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. R each i n behi nd t he con so le panel and lift the rele ase ( 1) to unplug the light f rom the harne ss. 3. Us ing a fl athead s crewdri ver , press on the ta b (2) on the top of the light to remove the indicator light asse mbly from the console pa nel. 4. Usi n[...]

95 MAINTENANCE AND LUBRICATION Cleaning Y our RANGER Keep ing your vehicle cle an will not only improve its appear anc e but it ca n also exte nd the lif e of va rious c omponents. W ith a fe w precautions , your vehicle can be cleaned mu ch lik e an automobile. The best a nd safe st way to clea n your ve hicle is with a garden hose and a pail of m[...]

96 MAINTENANCE AND LUBRICATION Sto rag e If your vehicle is to b e placed in ext ended or of f season st orage, th e following ste ps should be tak en to pre ser ve its condition. 1. Perfo rm all nec essa ry re pair s and thoroughly c lea n the ve hicle . 2. Remove the spar k plug and pour approximately one ounce of Premium 4 oil into the cylinder [...]

97 MAINTENANCE AND LUBRICATION Rem oval from S torage 1. Chec k the batter y elec trolyte le vel and cha r ge the ba ttery if nec essar y . Install it in the vehic le. Make sur e the batter y vent hose is routed pr operly a nd that it’ s not pinched or re stricte d in any wa y . 2. Make sure the spa rk plug is tight. 3. Fill the fue l tank with f[...]

98 MAINTENANCE AND LUBRICATION Batter y Kee p the ba ttery te rmina ls and conne ctions f ree of c orrosion. If clea ning is nece ssary , remove the c orrosion with a stif f wire br ush. W ash with a solution of one table spoon baking soda and one c up wate r . Ri ns e well wi th t ap wat er and dry o ff wi th cl ean sh op t owel s. C oat t he ter [...]

99 MAINTENANCE AND LUBRICATION Batter y Repl enishing B atter y Fl uid (Conv entional Batter y) A poorly ma intaine d batter y will dete riora te rapidly . C hec k the batte ry f luid leve l often. The fluid le vel should be ke pt betwe en the upper and lower le vel marks (1). T o re fill use only d istilled wa ter . T ap wa ter contains mine ra ls[...]

100 MAINTENANCE AND LUBRICATION Batter y Battery Installation 1. Set the batte ry in its holde r . 2. Install the batter y vent tube . It must be fr ee from obstruc tions and securel y i nst al led. If no t, batt ery gas es cou ld accu mu lat e and cause an explosion. The tube should be routed away fr om the frame a nd body to preve nt cor rosion. [...]

101 POLARIS PRODUCTS Part No. Descri pt ion Engine Lubr icant 2870791 Fogging Oi l ( 12 oz. Aerosol) 2871281 Premi um 4 Synt heti c 0W - 40 (4- Cycl e) Engi ne Oil (qt. ) 2871844 Premi um 4 Synt heti c 0W - 40 (4- Cycl e) Engi ne Oil (gal. ) Gearcase / T ransmi ssion Lubri cant s 2873602 Premi um AGL Synt het ic Gear case Lube ( qt. ) 2873603 Premi[...]

102 SPECIFICA TIO NS RANGER TM Gro ss V ehicle W eight 2400 lbs. (1089 kg) Fu el Capacity 8.5 gal . (32. 2 l) T owing Capac ity 1000 lbs. (454 kg) Max. Cargo Box Load 750 lbs. (340 kg) Over all Length 1 13 i n. (282 cm ) Overall Width (box) 60 in. (152. 4 cm) Over all W idth ( tires ) 58 in. (147. 3 cm) Over all Heig ht 51 in. (129. 5 cm) Wheelbas [...]

103 SPECIFICA TIO NS RANGER TM Lubricatio n Sy stem Full Pr e ssure Engine Oil 0W/40 Driv ing S ys tem T ype PVT Shift T ype Single Le ver (console ) Gear Reduc tion - L ow NA Gear Reduc tion - Re verse 6.84:1 Gear Reduc tion - High 4.71:1 Driv e Ratio - Fr ont NA Driv e Ratio - Fin al 3.70:1 Tire Size - Front 2 5x1 0-1 2 Tir e Size - Rear 2 5x1 1-[...]

104 SPECIFICA TIO NS RANGER 2x4 Gro ss V ehicle W eight 2500 lbs. (1 135 kg) Fu el Capacity 8.5 gal . (32. 2 l) T owing Capac ity 1400 lbs. (636 kg) Max. Cargo Box Load 850 lbs. (386 kg) Over all Length 1 13 i n. (282 cm ) Overall Width (box) 60 in. (152. 4 cm) Over all W idth ( tires ) 58 in. (147. 3 cm) Over all Heig ht 75 in. (190. 5 cm) Wheelba[...]

105 SPECIFICA TIO NS RANGER 2x4 Lubricatio n Sy stem Dry Sump Engine Oil 0W/40 Driv ing S ys tem T ype PVT Shift T ype Single Le ver (console ) Gear Reduc tion - L ow 8.71:1 Gear Reduc tion - Re verse 5.9:1 Gear Reduc tion - High 3.83:1 Driv e Ratio - Fr ont NA Driv e Ratio - Fin al 3.70:1 Tire Size - Front 2 5x1 0-1 2 Tir e Size - Rear 2 5x1 1-1 2[...]

106 SPECIFICA TIO NS RANGER 4X4 Gro ss V ehicle W eight 2700 lbs. (1226 kg) Fu el Capacity 8.5 gal . (32. 2 l) T owing Capac ity 1500 lbs. (681 kg) Max. Cargo Box Load 1000 lbs. (454 kg) Over all Length 1 13 i n. (282 cm ) Overall Width (box) 60 in. (152. 4 cm) Over all W idth ( tires ) 58 in. (147. 3 cm) Over all Heig ht 75 in. (190. 5 cm) Wheelba[...]

107 SPECIFICA TIO NS RANGER 4X4 Lubricatio n Sy stem Dry Sump Engine Oil 0W/40 Driv ing S ys tem T ype PVT Shift T ype Single Le ver (console ) Gear Reduc tion - L ow 8.71:1 Gear Reduc tion - Re verse 5.9:1 Gear Reduc tion - High 3.83:1 Driv e Ratio - Fr ont: 3.83:1 Driv e Ratio - Fin al 3.70:1 Tire Size - Front 2 5x1 0-1 2 Tir e Size - Rear 2 5x1 [...]

108 TROUBLE S HOOTIN G Contact your Polaris dea ler for se rvice if you’ re unable to identif y solutions using the following c har ts. Engine Doesn’t T urn Over Possi bl e Cause Sol utio n Tripp ed circuit b reak er Reset th e b reak er Lo w b attery v o ltage Rec ha r ge ba tt e ry t o 12. 5 VDC Loose ba t te ry c onnec tions Ch eck all con n[...]

109 TROUBLE S HOOTIN G Engine Backfires Possi bl e Cause Sol utio n W e a k spa rk fr om s pa rk pl ugs In sp ect, clean and /o r replace spark p lug s Inco rrect spark p lu g g ap o r heat rang e Set ga p t o spe c s or r e pl ac e plugs Old or non-re comme nde d fue l Repl a c e wit h new fue l Inco rrectly in stalled sp ark plu g w ires See your[...]

11 0 TROUBLE S HOOTIN G Engi ne Stops or Loses P owe r Possi bl e Cause Sol utio n Out of fuel Ref uel Kinke d or plugge d fue l vent l i ne Inspect an d replace W ater p resent in fu el Repl a c e wit h new fue l Ove rus e of c hoke Insp ect, clean and /o r replace spark p lu g s Foule d or de fe c t ive spar k pl ugs Insp ect, clean and /o r repl[...]

111 WARRANTY LIM ITED W ARRANT Y Pola r is Sal es Inc ., 2100 Highw ay 55, Me di na, M N 55340, give s a SI X MONTH LIM - ITED W ARRAN TY on al l c ompone nt s of the Pol ar i s RANGER against d efects in mate- ri a l or wor kma nshi p. Thi s wa rr a nty cove rs the pa r ts a nd la bor c har ges f or r epa i r or replacem en t of defectiv e parts w[...]

11 2 WARRANTY LIM IT A TIONS O F W ARRANT IES AND REMEDIES ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LI MITED T O THE I M- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TI CU- LAR PURPOSE) ARE LIMI TED I N DURA TION T O THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA NT IE S NO T S T A T ED [...]

11 3 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORI ZED LOCA TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t f r om Pola r is [...]

11 4 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent Y our W a rranty Rights a nd Obligati ons The C al i for ni a Air Resour c e s Boa rd and Pol a ri s Indus t r ie s Inc . , 2100 H ighwa y 55, Me dina , Mi nnes o ta 55340 (her e in “ POLARIS” ) a r e ple a se d t o e xpla i n the emi ss i on cont r ol s ys t em wa rr a nty [...]

11 5 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent W arra nty Period This war ra nt y pe ri od be gins on the da te, which t he LSI engi ne is del ive r ed, to the origi - nal retail pur chaser and en d s two y ears after th at date. Durin g th is two y ear perio d PO L AR IS w arran ts to th e o rig inal retail p u rch aser an [...]

11 6 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent What is Not Cove red Unde r Thi s W arranty This war ra nt y doe s not cove r a ny e mi s si on- re lat e d par t , whic h ma l f unct i ons , f a il s , or is dam age d due to al te r a ti ons a nd/or m odif i ca tions s uc h as cha nging, addi ng, or re movi ng par t s . Whe n[...]

11 7 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent Main tena nce S che dule Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) " E Engine oil lev el -- Pre- Ride -- Mak e adjustments as need- ed. See Pre-R ide Chec k lis t on page 33. " E Air filter , pre-filter -- Daily -- Ins p[...]

11 8 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent Repair and R eplacemen t of Em ission- R elated Part s It is reco mm en ded t hat on ly L S I eng in e replacemen t parts, wh ich h av e been au tho rized and a ppr ove d by POLARI S, should be used i n t he per f or ma nce of a ny wa rr a nt y main ten ance o r rep airs o f em [...]

11 9 WARRANTY U.S. A. EP A Emiss i on s L i mit e d W arra n ty Th is Al l T errain V eh icle (A TV) o r O ff Road U tility V eh icle (OR UV ) emissio n s limited warran ty is in add ition to th e Po laris standard lim ited warran ty fo r this veh icle. Po laris w arrants t hat th is v eh icle is; (1 ) d esign ed , b u ilt, and equ ip p ed to con f[...]

120 MAINTENANCE LOG Per iodic Mainten ance Record Use th e fol lo wing ch art t o reco rd peri odi c m aint enan ce. DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

121 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

122 INDEX A Ag e R estriction s 5 ................. Air F ilter ( 2x4, 4X4) 78 ............. Air F ilter (TM ) 8 0 ................. All Whe el Dr ive ( A WD) 49-50 ........ Au x iliary Ou tlet 26 ................ A WD Swi t c h (4X4) 30 ............. B Bat t er y 98- 100 .................... Battery F lu id 9 9 ................... Battery In stall[...]

123 INDEX N Nois e Emi s s ion Contr ol Sys te m 52 .... O Oil an d F ilter C han g e ( 2x4, 4X4) 62- 63 . Oil an d F ilter C han g e (T M) 66 -6 7 ..... Oil C hec k (2x4, 4X4) 61 ............ Oil C h eck (T M ) 6 5 ................ Oil Pump Pri mi ng (2x4, 4X4) 64 ...... Ope ra t or Saf e t y 5-17 ................ P Par ki ng Bra ke Adjus t me nt [...]