Polaris RANGER XP 4X4 700 EFI 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 33 .............................. EMISSI ON CONT ROL SYSTEM S 52 ............ MAINTENANCE AND LUBRICA TION 53 ......... POLARIS PRODUCTS 99 ...................... 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 . Engage the par k brak e aft er 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 pl aced on t he RANGER for your protection. Read an d fol lo w the i nst 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 anu al di ffer from th e decals o n your RANGER , always r ead a nd follow the instruc tions of the decal [...]

19 SAFE TY Safety D ecals and Locations W ARNING S VEH ICLE R OLLO VE R c ould c ause s ev ere injur y or deat h. This c ab frame is not des igned or intended to pr ovide r ollov er protec tion. S AL WA YS WEAR YO UR SEA T BEL T for maximu m prote ction. 7172676 Lo cati on 2 Loca tion 3 (inside f ront of box) Container/Passenger/T ire P ressur e W [...]

20 SAFE TY Safety D ecals and Locations Loca tion 5 (under hood) 5 6 Lo cati on 6 Lo cati on 7 A TTENTION S Operat ion of this v ehic le wit hout the air filt er element will s ev erely damage the engine. S Clean pre- filter element often, mor e frequent c leaning requir ed in dus ty conditi ons. D o not operat e vehic le w ithout pre-filt er . 717[...]

21 SAFE TY Safety D ecals and Locations Discretionar y W arning Decal 7 8[...]

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 100. Com ponent Locations 1. Cab Frame (if equippe d) 2. Hip Bar 3. Console 4. S t eerin g Wheel 5. S eat 6. Storage Box (under drive[...]

24 FEATURES AND CONTROLS Com ponent Locations 12. Headlights 13. Radiator (if equippe d) 14. Front Bumper/Brush Guard 15. Hood Hold Down S trap 14 13 12 15[...]

25 FEATURES AND CONTROLS Com ponent Locations 16. T aillights 17. T ailga te 18. T ail gat e Lat ch R eleas e 19. Muf fler ( Spark Ar re ster) 20. CV Boot/Rear Ca liper 21. Air Box 22. Recei ver Hi t ch 16 16 22 19 18 20 20 21 17[...]

26 FEATURES AND CONTROLS Indicator Lights 1. High Gear 2. L ow Gear 3. Neutral G ear 4. Reverse Ge ar 5. High T empe rature 6. Park Brake 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 with this ve hicle . T o avoid injury a nd proper ty da[...]

27 FEATURES AND CONTROLS Fuel Cap/Fuel Gauge The f uel tank f iller c ap ( 8) is loca ted on the right-ha nd side of the vehicle ne ar the passe nger sea t. It has a built-in fuel gauge that indica tes the amount of fuel rema ining in the tank. When t he i nd icat or n eedl e nears t he E (empt y) mark , refuel at t he earli est opportunity . When [...]

28 FEATURES AND CONTROLS Seat Belts The RANGER is equipped with lap-style sea t belts for the opera tor and passenge r . W ARNING Falling f rom a m oving vehic le could res ult in s erious injur y or death. Always f ast en your seat belt sec urely bef ore oper ating or riding in t he RANG ER . Passenger s under f ive year s of age r equire spec ial[...]

29 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. Ignition Switch 1 1. Storage Box 10 6 2 8 3 7 11 1 4 5 1 9[...]

30 FEATURES AND CONTROLS Gear Selector H: High Gear L: Low Gear N: Neutral R: Rev er se NOT E: Low gear is t he primar y driving r ange for t he RANGE R XP . High gear is intended f or use on hard-pac ked sur fac es with light loads. T o change ge ar s, stop the vehicle , and with the engine idling, move the lever to the desir ed ge ar . Do not att[...]

1 2 3 31 FEATURES AND CONTROLS Switches Ignition S wi tch (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 Engine off. All elect ric al circ uits are off except Acc . 12V . ON/R UN Electric al circ uits ar e on. Elect ric al equipment can be us ed. ST A[...]

1 2 3 4 32 FEATURES AND CONTROLS Br ake Pedal (1) Depre ss the brake ped al to slow or stop the vehicle . Apply the brakes while star ting the engine. 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 norma[...]

33 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 a ction on your pa rt is as impor tant as a proper brea k-in pe riod. Care ful tre atme nt of a new e ngine will r esult in mor e ef ficient p[...]

34 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 82 Bra ke [...]

35 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. 1. S i t i n th e driv er ’ s s eat an d fast en th e seat bel t . 2. Engage the par k brake. 3. Shift the tra nsmission to ne[...]

36 OPERATION Stoppi ng the Engi ne 1. Rele ase the throttle pe dal comple tely and brak e to a complete stop. 2. T urn the engine off . 3. Engage the par k brake. W ARNING A rolling v ehicle can c ause proper ty damage and s erious injur y . Always engage t he park br ake af ter st opping t he engine. Br aking 1. Rele ase the throttle pe dal comple[...]

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. After starting the e ngine a nd allowing it to war m up, apply the serv ice br ake s, and shift the tr ansmission into ge ar . 3. Check your surroundings and de termine your path of trave l. 4. Release the pa rk brake . 5. Keep in[...]

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. Engage the par k brake. 3. T urn the engine off . 4. Block the rear whee ls on t he downhill side. W ARNING A rolling v ehicle can c ause proper ty da[...]

45 OPERATION Driving Safely 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: REDUCE SPEED AND ALLOW G REA TER DI ST ANCES F OR BRAKING WHEN H AULING CAR GO. Alwa[...]

46 OPERATION Driving Safely Hauling Cargo The RANGER has bee n designed to c arr y or tow spe cific capa citie s. Always re ad a nd understa nd the load d istribution wa rnings listed on the warn in g label s. Nev er exceed th e foll owi ng cap ac ities. Maxi mum Cap aci ties (L evel Gr ound) Cargo Bo x RANGE R 4X4 XP 1500 lbs. ( 681 kg) 1000 lbs. [...]

47 OPERATION Driving Safely 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 d[...]

48 OPERATION Driving Safely 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 [...]

49 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 engage t he park br ake af ter st opping t he engine. 1. S t op t he v ehi cle o n a l evel s urface. 2. T urn the engine off . 3. Engage the par k brake. 4. Remove the i gnition switch ke y to pre vent una uthori[...]

50 OPERATION Differ ential Lock (4X 4) The 4X4 rear a xle is equipped with a lockable dif fe rentia l that allows the oper ator to c hoose betw een an open d ifferenti al o r a closed dif fe re ntial. It’ s benefic ial to lock the dif fe re ntial in low tra ction s ituations. Move the A WD/Dif fere ntial Lock roc ker sw itch to the ce nte r posit[...]

1 51 OPERATION All Wheel Drive ( A WD) The illumina ted a mber A W D switc h (1) indica tes that the vehic le is in A WD. Whe n the A WD switch is on, the front whe els will a utomatic ally e ngage any time the r ear wheel s l ose t ract ion . When t he rear wheel s regai n t racti on , t he fron t whee ls will au tomatic ally disenga ge. Ther e is[...]

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 Control System Servic e - 4 Cycle (Califor nia) J Have an au th ori zed P ol aris deal er perfo rm t hes e serv ices . W ARNING Im properly perf orm ing th[...]

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 -- Ins pect ; replac e if neces s ary " Engine oil c hange (brea k-in) 25 H 1M -- Perform a break - in oil change at one month " G[...]

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 -- Chec k for leaks at tank c ap, lines, fuel v alv e, filter, pump, throttle body ; r eplace lines ever y t wo y ears J Fuel filter 100 H 12 M -- Replace 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) (3) 6X6 4X4 6X6 6X6 6X6 (2) 4X4 6X6[...]

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[...]

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 The oil dipstick a nd fill tube ( 1) is loca ted on the e ngine. 1. Position the vehicle on a lev[...]

62 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Chang e CAUTION Hot oil c an cause ser ious burns t o sk in. Do not allow hot oil t o come int o cont act wit h sk in. Alwa ys change the oil and filte r at the interva ls outlined in the Periodic Maintena nce Char t beginning on page 53. Always change the oil filter whenev er chang in g oi [...]

63 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Chang e 12. Remove the dipstick a nd fill the sump with tw o quar ts (1.9 l) of rec omme nded oil. 13. Shift the tra nsmission to neutra l. 14. Engage the park bra ke. 15. Apply the brakes. Start the engine. Allow it to idle for one to two minutes. 16. Stop the engine. Inspect for lea ks. 17[...]

1 64 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 . The fi ll plu g (1 ) is l ocat ed at t he rear o f the vehic le. Refer t o[...]

65 MAINTENANCE AND LUBRICATION Gearcases T ransmission (Main Gear case) Oil Chan ge The dra in plug (2) is loca ted on the bot to m o f th e tran sm is si on . Access t he drain plug through the drain hole i n the ski d pl at e. 1. Remove the fill plug. 2. Place a dra in pan under the drain plug. Remove the dra in plug. Drain the oil. Dispose of us[...]

1 2 66 MAINTENANCE AND LUBRICATION Gearcases Front Gearcase 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. The front gea rca se fill plug (1) is l ocate d on the right side of th[...]

67 MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase ( RANGER 6X6) Always ch eck an d chan ge th e mi dd le g earcase oi l at t he i nt ervals 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. Refer t o t he Gearcas e Sp ecifi cati on s C hart o n pag[...]

1 2 1 2 6X6 4X4 68 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 Maintena nce Cha rt beginning on page 53. Refer t o t he Gearcas e Sp ecifi cati on s C hart o n pag e 63 fo r rec ommende d lubric ants, ca pac ities and tor que spe cific ations. See [...]

69 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Oil Chan ge 1. Remove the fill plug. 2. Place a dra in pan under the drain plug (2). Remove the drain plug. 3. Drain the oil. Dispose of used oil properly . 4. Clean the dra in plug. Reinstall the drain plug. T orque to speci ficat i on. 5. Add the re comme nded oil. 6. Reinstall the fill plug.[...]

70 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 100. Spark P lug Ga p/T orque Model Elect r ode Gap New P lug T or que Used Plug T orque RANGER 4X4 XP .035 ″ (.9[...]

71 MAINTENANCE AND LUBRICATION Spar k Pl ugs 2. W et Foule d The w et foule d insulator tip is black. A da mp oil film cove rs the f iring end. There may be a ca rbon laye r over the entire nose . Genera lly , the elect rodes are n ot wo rn. General causes of fou li ng are exces si ve o il , use of non-re comme nded injec tion oil or incorrec t thr[...]

72 MAINTENANCE AND LUBRICATION Cooling System 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) excess co ol[...]

73 MAINTENANCE AND LUBRICATION Cooling System 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 he radi ato r[...]

1 74 MAINTENANCE AND LUBRICATION Cooling System 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 engine to c o[...]

75 MAINTENANCE AND LUBRICATION Polar is V ar iable T ransm ission (PV T) System Belt slip is r esponsible for c rea ting e xcessive heat that de stroys be lts, wear s clutc h compone nts and ca uses oute r c lutch cove rs to fa il. Switch to low range while ope ra ting at slower spee ds to extend the life of the PVT compone nts ( belt, cove r , etc[...]

76 MAINTENANCE AND LUBRICATION 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 precisio n balanced. Any modif icati[...]

77 MAINTENANCE AND LUBRICATION PV T System PVT Dryin g There may b e som e ins tan ces when wat er is acci dent ly i ng est ed in to the PVT system. Use the following instructions to dry it out before opera ting. 1. Loosen the bottom screws that sec ure the clutc h cover . 2. Allow the wate r to drain. 3. Tighten t he s crews. 4. Apply the brakes. [...]

1 78 MAINTENANCE AND LUBRICATION Filter System s 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 way a round. [...]

79 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[...]

1 2 80 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[...]

81 MAINTENANCE AND LUBRICATION Throttle S ystem Throttl e Fre eplay A djustm ent 1. Slide the boots (1) off the inline ca ble adjuste r slee ve (2). Loosen the adjuster loc knut (3). 2. T urn the adjuste r until 1/16 to 1/8 inch f ree play is a chie ved. NOT E: W hile adjust ing, f lip t he thr ott le lever back and f ort h. 3. T ighten the locknut[...]

1 82 MAINTENANCE AND LUBRICATION Br akes The front and rea r bra kes are hydr aulic disc type bra kes and ar e activa ted by the brake pe dal. See page 32. 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 the bra ke flui[...]

83 MAINTENANCE AND LUBRICATION Br akes Brake Inspection 5. Chec k the brake syste m for fluid leak s. 6. Check the bra ke pedal for exc essive trave l or a spongy feel. 7. C heck t he frict i on pad s for wear , damage a nd looseness. 8. Inspec t the brake disc spline a nd pad wear s urface fo r exces si ve wear . 9. Change pads whe n worn to 3/64 [...]

84 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 [...]

85 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[...]

86 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 mm) or le ss. Im proper t ire inf lat ion or the us e of non-[...]

87 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 88 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 89 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. Apply the brakes. Start the engine.[...]

90 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[...]

91 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[...]

92 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 [...]

93 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[...]

94 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. A[...]

95 MAINTENANCE AND LUBRICATION Cleaning and S tor age See page 99 for the pa rt numbers of Polaris products. Cleaning th e RANGER Keeping your RANGER clea n will not only improve its appeara nce but it can a lso exte nd the lif e of va rious c omponents. W ith a fe w precauti ons, your RAN GER can be clean ed mu ch li ke an aut om ob il e. W ashin [...]

96 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s CAUTION Star ting t he engine during t he st orage per iod will dist urb t he prot ecti ve film c reated by f ogging and damage c ould occur. Nev er star t t he engine during t he st orage per iod. Clean t he Exter ior Make ne ce ssar y repa irs a nd then cle an the vehic le thor[...]

97 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s Fog the Engi ne 1. T reat the fuel syste m with Polar is Carbon Clea n, following the instructions on the ca n. Run the engine for se ver al minutes so the Carb on C l ean reaches t he i nj ecto rs. T urn t he eng in e off. 2. Remove the spa rk plugs and a dd 2-3 table spoons of [...]

98 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[...]

99 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 [...]

100 SPECIFICA TIO NS RANGER 4X4 X P Gro ss V ehicle W eight 2750 lbs. (1247 kg) Dry W eight 1 185 l bs. (537 kg) Fu el Capacity 8g a l .( 3 0 . 3l ) Engine Oil Ca pacit y 2q t s . ( 2 . 1l ) Coo lant Capacity 3.25 qts. (3 l ) T owing Capac ity 1500 lbs. (681 kg) Hitch T ongue Capaci ty 150 lbs. (68 kg) Max. Cargo Box Load 1000 lbs. (454 kg) Over al[...]

101 SPECIFICA TIO NS RANGER 4X4 X P Lubricatio n Sy stem Pr ess urized W et Sump Engine Oil 0W/40 Driv ing S ys tem T ype PVT , 4-wheel indepe ndent shaft, lockab le dif fer ential Shift T ype Sin gle Lever (H /L/N/R ) Gear Reduc tion - L ow 8.71:1 Gear Reduc tion - Re verse 5.94:1 Gear Reduc tion - High 3.14:1 Driv e Ratio - Fr ont: 3.83:1 Driv e [...]

102 SPECIFICA TIO NS RANGER 6X6 E FI Gro ss V ehicle W eight 2900 lbs. (1317 kg) Dry W eight 1410 lbs. (640 kg) Fu el Capacity 8g a l .( 3 0 . 3l ) Engine Oil Ca pacit y 2q t s . ( 2 . 1l ) Coo lant Capacity 3.25 qts. (3 l ) T owing Capac ity 1750 lbs. (794 kg) Max. Cargo Box Load 1250 lbs. (567 kg) Over all Length 120 in. (304. 8 cm) Overall Width[...]

103 SPECIFICA TIO NS RANGER 6X6 E FI Front Sus pension MacPherson strut w/6.25 in. (15.9 cm) of t ravel Center S us pens ion Independe nt w/5.25 in. (13.3 cm) of t ravel Rear S usp ens ion Swing arm w/dual shocks w/6.25 in. (15.9 cm) of t ravel 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[...]

104 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 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 ection s and tig h ten Loose s ol e noid conne [...]

105 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 pl ugs Old or non- r ec omm ende d fuel Repl a c e wit h new fue l Inco rrectly in stalled sp ark plu g w ires See yo[...]

106 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 Foule d or de fe c t ive s pa rk pl ugs Insp ect, clean and /o r replace spark p lu g s W or n or de fec t ive s pa rk pl ug wi r e s Se [...]

107 WARRANTY LIM ITED W ARRANT Y Pola r is Sa l e s Inc . , 2100 Highwa y 55, Medi na , MN 55340, give s a SIX MONTH LIM - ITED W ARRAN TY on al l c ompone nt s of the Pol a ri s RANGER again st d efects in m ate- 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 part[...]

108 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 I[...]

109 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 I[...]

11 0 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[...]

111 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 Re sour c e s Boar d a nd Pola r i s I ndus tr i e s I nc ., 2100 Hi ghwa y 55, Me - dina , Mi nnes ot a 55340 (he r ei n “ POLARI S” ) a r e ple a s ed t o e xpla in the e mis s i on cont r ol sys t e m wa r r[...]

11 2 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent Owner ’ s W a rranty Responsibilities : S As the L SI engi ne owne r , you ar e re s pons ibl e f or the pe r f orm anc e of t he re qui r ed ma int e na nce l is ted i n your Owne r’ s Sa f e ty a nd Ma i nte nance Ma nua l (he r e in “ Own- er’s Manu al”). PO L AR IS[...]

11 3 WARRANTY Cal ifor nia E mi ssion C ontrol W ar r anty S tatem ent Emission- Related Part s Covered U nd er This W arran ty (1) Fu el Meterin g S y stem (i ) Ca r bure t or a nd inte r na l par t s ( and/ or pr e ss ur e r e gula t or or fue l i nj ec t i on syst e m) . (ii) Air/fuel ratio feedb ack an d co ntro l system , if ap p licab le. (ii[...]

11 4 WARRANTY What is Not Cove red Unde r Thi s W arranty This wa r ra nt y doe s not c ove r a ny emis s i on-r e l at e d pa rt whi c h ma lf unc t ions , fa i ls or i s dam age d due to a l te r a ti ons a nd/or modi f ic a t ions s uc h as c ha nging, a dding or r e movi ng par t s . Whe n the LSI engi ne i s be i ng se rvic e d under wa r ra n[...]

11 5 WARRANTY Main tena nce S che dule Ke y " Perf or m these pr ocedur es mor e oft en for vehicles subj ected t o sever e use. E Emissi on Cont rol System Servi ce (Cal i for nia) J Have an author ized Pol ar is deal er per f orm t hese servi ces. Item Maintenance I nt erval (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) &quo[...]

11 6 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[...]

11 7 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

11 8 INDEX A Ag e R estriction s 5 ................. Air F ilter 78 ...................... All Whe el Dr ive ( A WD) 51 .......... Au x iliary Ou tlet 26 ................ A WD S w itch 31 ................... B Bat t er y 92- 94 ..................... Battery F lu id 9 3 ................... Battery In stallatio n 94 .............. Bat te r y Remova l[...]

11 9 INDEX N Nois e Emi s s ion Contr ol Sys te m 52 .... O Oil an d F ilter Ch an g e 62-6 3 .......... Oil C h eck 61 ..................... Ope ra t or Saf e t y 5-17 ................ P Par k Bra ke Adjus t me nt 83 ........... Park Brak e In spectio n 83 ............ Park Brak e P ed al 32 ................ Park Brak e R elease 32 .............. [...]