Polaris 2005 99 Ranger manual

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

FOREWORD Congratulations and thank you from Polaris Industries Inc. for purchasing one of our products. Built with American engineering and manufacturing know-how , i t i s designed to provide superior comfort, utility , enjoyment and safety . This manual is furnished to ensure that the operator is aware of safe operating pro- cedures. It also incl[...]

THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS T O OPERA T E. This vehicle handles differently from other vehicles including motor- cycles and cars. A collision or rollover can occur quickly , even during rou- tine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEA TH can r[...]

 Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.  Al[...]

indicates a potential hazard which could result in serious injury or death. W ARNING Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris RANGER any equipment which is intended to increase the spee[...]

The Polaris Preferred Registered Owners (PRO) Family Y our Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family- – the Preferred Registered Owners Family . I t ’ s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle ava[...]

CONTENTS UNDERST ANDING W ARNINGS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY W ARNING AND OPERA TION DECALS 2-7 . . . . . . . . . . . . LABEL LOCA TIONS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAIL Y PRE-RIDE INSPECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERA TION[...]

1 UNDERST ANDING W ARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury . Y our safety is involved! W ARNING Indicates a potential haz[...]

2 SAFETY W ARNING AND OPERA TION DECALS VEHICLE ROLLOVER COULD CAUSE SEVERE INJUR Y OR DEA TH This cab frame is not designed or intended to provide rollover protection in the event of vehicle overturning. See Owner ’ s Manual. W ARNING l Riders can be thrown of f. This can cause serious in- jury or death. l Never carry riders in cargo box. IMPROP[...]

3 SAFETY W ARNING AND OPERA TION DECALS Recoil handle must be firmly seated to prevent water entry . Drain starter motor if water enters. See owner ’ s manual. 7075741 W ARNING/A VERTISSEMENT 7075439 This vehicle is designed for operator and “ ONE ” passenger only Ce V ehicule est concu pour ne transporter que le conducteur et “ UN SEUL ”[...]

4 SAFETY W ARNING AND OPERA TION DECALS T ext found below 7077683 OPERA T OR/LOAD DISTRIBUTION W ARNINGS VIOLA TION OF ANY OF THE FOLLOWING W ARNINGS COULD CAUSE LOSS OF CONTROL AND RESUL T IN SEVERE INJURY OR DEA TH. MAKE S T AR TS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTH MANNER so as not to shift the load or overturn the vehicle. THE FOOT[...]

5 SAFETY W ARNING AND OPERA TION DECALS THE ABILITY T O STEER THIS MACHINE IS REDUCED WHEN OPERA TING IN A LOADED CONDITION on rough or hilly terrain. When climbing hills always hav- in g the cargo in the rear box securely fastened and located as far forward in the box as possible. Loaded vehicles will experience reduced steering and front brake ef[...]

6 SAFETY W ARNING AND OPERA TION DECALS T ext found below 7077680 READ AND UNDERST ANDING WARNINGS AND OWNER ’ S MANUAL BEFORE OPERA TION. SEVERE INJURY OR DEA TH CAN RESUL T FROM IGNORING W ARNINGS O R I MP ROPER USE. If you do not have the Owner ’ s Manual for this vehicle, call 1-800-324-3674 to have one provided at no extra charge.  This[...]

7 SAFETY W ARNING AND OPERA TION DECALS  OPERA TION ON HILLS IS DANGEROUS, especially when loaded. This vehicle is designed for utility usage on moderate terrains. Turning, braking and uneven terrain can induce rollovers especially if a maneuver is abrupt. Under no circumstances should you climb, descend or traverse hills greater than 15 ° ∠ [...]

8 LABEL LOCA TION 2 4 6 5 1 3 1. W arning (General) 2. W arning (V ehicle roll-over) 3. W arning (Load Distribution) 4. W arning (Cargo Bed) 5. Tire Pressure 6. T owing Information[...]

9 DAIL Y PRE-RIDE INSPECTION Inspect your vehicle each time before riding to ensure it is in proper working order . If proper inspection is not done, severe injury or death could result. If a proper inspection is not performed serious injury or death can result. Always inspect your RANGER before riding following the checklist care- fully . Before r[...]

10 OPERA TION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operating this vehicle without proper instruction. WHA T CAN HAPPEN Th e risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on d if fer- ent types of terrain. HOW T O A VOID THE HAZARD Read and understand th[...]

11 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHA T CAN HAPPEN This vehicle ’ s tires are designed for of f-road use only; not for use on pavement. Paved surfaces may seriously af fect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW T O A VOID THE HAZARD Always[...]

12 OPERA TION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs. WHA T CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly . Could affect your balance and perception. Could result in an accident. HOW T O A VOID THE HAZARD Never consume alcohol or drugs before or wh[...]

13 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHA T CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW T O A VOID THE HAZARD Always inspect your RANGER each time you use it to make sure it is in safe operating condition. Always f[...]

14 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip- pery or loose terrain. WHA T CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW T O A VOID THE HAZARD Do not operate on excessively rough, slippery or loose ter[...]

15 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Climbing hills improperly . WHA T CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW T O A VOID THE HAZARD Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly . The vehi[...]

16 OPERA TION W ARNINGS W ARNING W ARNING W ARNING POTENTIAL HAZARD Improperly operating over obstacles. WHA T CAN HAPPEN Could cause loss of control or a collision. Could cause vehicle to overturn. HOW T O A VOID THE HAZARD Before operating in a new area, check for obstacles. Us e extreme caution when riding over large obstacles, such as large roc[...]

17 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW T O A VOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner[...]

18 OPERA TION W ARNINGS W ARNING POTENTIAL HAZARD Operating this vehicle with improper modifications. WHA T CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW T O A VOID THE HAZARD Never modify this vehicle through improper installatio[...]

19 OPERA TION W ARNINGS POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly . WHA T CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW T O A VOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce spee[...]

20 VEHICLE IDENTIFICA TION NUMBERS Important: Record these numbers from your vehicle in the spaces provided. 1. Frame VIN: 3. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Record your ignition key num- ber here. It is a four digit number found stamped on the key . In the event the ke y i[...]

21 CONTROL P ARTS AND FUNCTIONS Fuel Gauge The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank. When the red indicator needle comes near the E (empty) mark, refuel at the earliest opportunity . Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF pos[...]

22 CONTROL P ARTS AND FUNCTIONS Parking Brake Lever Th e parking brake lever is located at the right side of the driver ’ s seat. Pull the lever up and to the rear to apply the parking brake. T o release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return the lever to the released p[...]

23 CONTROL P ARTS AND FUNCTIONS Seat Belts The vehicle is equipped with lap-style seat belts for the operator and passenger . W ARNING Seat belts reduce injury . Always were your seat belt. Minimum age recommen- dation for passengers if five years old. Passengers under five years of age re- quire special restraints which are not available with this[...]

24 CONTROL P ARTS AND FUNCTIONS Engine Fuel and Oil System The fuel tank filler cap (1) is lo- cated on the left side by the driv- er s seat. Use either leaded or un - leaded gasoline with a minimum pump octane number of 87 R+ M/2 octane. Th e fuel supply valve (2), located in the center console storage compartment (A) has three posi- tions: OFF: F[...]

25 CONTROL P ARTS AND FUNCTIONS W ARNING Gasoline is highly flammable and explosive under certain conditions.  Always exercise extreme caution whenever handling gasoline.  Always refuel with the engine stopped and outdoors or in a well venti- lated area.  Do not smoke or allow open flames or sparks in or near the area where refueling is pe[...]

26 CONTROL P ARTS AND FUNCTIONS Never use gasohol with an octane rating lower than the minimum octane rat- ing specified for this product. Never use gasohol containing more than 10% ethanol (grain alcohol). Never use gasohol containing more than 5% methanol (wood alcohol). Gas- oline containing methanol must also be blended with cosolvents and corr[...]

27 CONTROL AND P ARTS FUNCTIONS VEHICLE NOMENCLA TURE - Left View 1. Cab Frame 2. Cab Frame Hand Hold 3. Dashboard 4. Steering Wheel 5. Gear Shift Lever 6. Seat 7. Cargo Box 8. Seat Belts 9. Parking Brake 10. Engine Compartment Access Panel 1 1. Hood Latches (attached to hood; left and right sides under dash) 1 10 4 8 6 7 9 11 5 2 3[...]

28 CONTROL AND P ARTS FUNCTIONS VEHICLE NOMENCLA TURE - Front View 14 16 15 13 12 12 12. Headlights 13. Air Box (under hood) 14. Battery (under hood) 15. Radiator (under hood) 16. Front Bumper/Brush Guard[...]

29 CONTROL AND P ARTS FUNCTIONS VEHICLE NOMENCLA TURE - Rear V iew 17 18 21 20 19 17 17. T ail Gate Latches (T op and Bottom) 18. T ail Gate 19. Muffler (Spark Arrester) 20. Trailer Hitch Receiver 21. T aillight[...]

30 CONTROL AND P ARTS FUNCTIONS VEHICLE NOMENCLA TURE - Instrument Panel 12 2 8 11 1 3 7 5 6 9 4 10 1. Choke Knob 2. Ignition Switch 3. Hour Meter 4. Passenger W arning Decal 5. Neutral Indicator Light 6. Reverse Indicator Light 7. Brake Light 8. Coolant T emperature Warning Light 9. Fuel Gauge 10. 12V Accessory Plug 1 1. Fog/High Beam Light Switch[...]

31 CONTROL AND P ARTS FUNCTIONS Demand 6 Drive Exclusive Demand 6 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 6 Drive (AWD) system which is activated by a switch on the dash. When the switch is “ of f ” the RANGER is in 4 wheel drive at all times. When the switch is “ on ” the RANGER [...]

32 CONTROL AND P ARTS FUNCTIONS T ransmission Gear Selector Operation Th e transmission gear selector is located to the right of the vehicle driver ’ s seat. The transmission selector lever has four posi- tions: high forward (D2); reverse; neutral; and low forward (D1). Use of (low forward gear - D1) is recom - mended i n heavy pu lling situa tio[...]

33 CONTROL AND P ARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 6 Drive and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again. Y o u can tell if only one front hub is enga[...]

34 CONTROL AND P ARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle (1), located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle. The engine coolant level is con- trolled or maintained by the re- covery system. The recovery system components are the re- c[...]

35 CONTROL AND P ARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair . However , if the recovery bottle has run dry , the level in the radiator should be inspected and coolant added if necessary . W ARNING Never remove the p[...]

36 CONTROL AND P ARTS FUNCTIONS Engine Cooling System T o insure that the coolant maintains its ability to protect the engine, it is recom- mended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added. Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of[...]

37 CONTROL AND P ARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated fo r use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis- cosity oil designed to provide the ultimate in lubrication performance and protec- tion. Premium 4 possesses [...]

38 CONTROL AND P ARTS FUNCTIONS Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break in oil change is at 20 hours, 500 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dust[...]

39 CONTROL AND P ARTS FUNCTIONS Oil and Filter Change (Cont.) 14. Reinstall drain plug. 15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially . 16. Place gear selector in neutral and set parking brake. 17. Start engine and let it idle f[...]

40 ST ARTING THE ENGINE Stopping the Engine 1. Release the throttle pedal completely . 2. Put the gear shift lever into (N) Neutral. 3. Apply the parking brake to help prevent the vehicle from rolling. 4. Turn the ignition switch key to the OFF position. Procedure for Starting a Cold Engine W ARNING Do not start or operate this vehicle with stickin[...]

41 ST ARTING THE ENGINE 7. If engine does not start, release ignition switch and wait five seconds; then turn the ignition switch to start for another five seconds. Repeat this procedure until engine starts. NOTE: Do not press the throttle pedal while starting the engine. After the Engine Starts 1. If the engine slows or stops, use of the choke lev[...]

42 ST ARTING THE ENGINE Procedure for Starting a W arm Engine W arm engines do not normally require the use of the choke since the spark plug can easily become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake 3. Turn the fuel tank valve to ON. 4. Sit in the vehicle in the driver ’[...]

43 ST ARTING THE ENGINE Recoil Starter Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. 1. Be certain the parking brake is set. See page 27. 2. Remove right side engine access panel. See page 35. 3. Grasp the [...]

44 VEHICLE BREAK-IN PERIOD The break in period for your new Polaris RANGER is defined as the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treat- ment of a new engine will result in more ef ficient performance and [...]

45 CARR YING LOADS The RANGER has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights. Maximum Capacities (Level Ground) Cargo Box RANGER - 1500 lbs. (681 kg) 1000 lbs. (454 kg) Dumping the Cargo Box 1. Select a level site [...]

46 OPERA TING SAFETY Load Distribution 1. Always load the cargo box placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever hauling or towing loads. 3. Slow down and drive in D-1 only . 4. T he cargo box dump latch must be securely latched before loading and operat- ing. Unintentional box tilting will r[...]

47 OPERA TING SAFETY 1. Sit in the driver ’ s seat with the seatbelt fastened. 2. After starting the engine and allowing it to warm up, shift the transmission into gear . 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both hands on the steering wheel, slowly depress the throttle with your ri[...]

48 OPERA TING SAFETY Riding On Slippery Surfaces Whenever driving on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather , special attention must be paid to prevent vehicle turnover . Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, shar[...]

49 OPERA TING SAFETY Operating on Hills W ARNING Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur .  Avoid crossing the side of a steep hill if possible.  Use extreme care when operating your RANGER in hilly terrain. Whenever descending a hill always: 1. Drive di[...]

50 OPERA TING SAFETY Braking and handling are greatly af fected whenever operating in hilly ter- rain. Loss of vehicle control or overturning of the vehicle could occur .  Avoid climbing steep hills (15  maximum).  Use extreme care when operating your vehicle in hilly terrain. indicates a potential hazard which could result in serious inju[...]

51 OPERA TING SAFETY W ARNING Going down a hill improperly could cause loss of control or cause the ve- hicle to overturn. Always check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill whe[...]

52 OPERA TING SAFETY Crossing Streams Y o ur Polaris RANGER can operate through water up to depths reaching the floor- boards. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly , avoiding rocks and obstacles if possible. 4. After crossing, dry the bra[...]

53 OPERA TING SAFETY T rail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. W ARNING Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occu[...]

54 OPERA TING SAFETY Backing Up 1. When backing up, always avoid backing downhill. 2. Back slowly . 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision before backing. W ARNING Backing your RANGER [...]

55 OPERA TING SAFETY Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Stand clear and pull the cargo box release mechanism lever (1) forward. Lift the front of the cargo box to dump. W ARNING If the weigh[...]

56 NOISE EMISSION CONTROL SYSTEM REGULA TION T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair , or replacement of any device or element of design incorpo- rated into any new vehi[...]

57 BA TTER Y Battery CAUTION Whenever removing the battery , discon- nect the negative (black) cable first. When reinstalling the battery , connect the nega- tive (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly . Check the battery fluid level often. The fluid level should be kept between the u[...]

58 BA TTER Y Battery Removal 1. Disconnect hold down straps holding the battery (1) in position and remove battery retainer . 2. Remove the battery vent tube from the battery . 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) bat- tery cable next. 5. Lift the battery out of the vehicle, being careful not to t[...]

59 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important compo- nents are explained in the following chart: Maintenance intervals are based upon average riding conditions and a vehicle speed of approxima[...]

60 MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Odometer Frequency Remarks   Fuel System 100 hours 12 months Check for leaks at fuel cap, lines, fuel valve, filter, pump and carburetor. Re- place lines every two years.  Fuel Filter 100 hrs 12 months Replace annually  Carburetor Float Bowl 50 hrs 6 months Drain bowl pe[...]

61 MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Odometer Frequency Remarks Headlamp Inspection Daily Daily Check operation daily; apply Polaris di- electric grease to connector when re- placed T ail lamp inspection Daily Daily Check operation daily; apply Polaris di- electric grease to socket when replaced Brake System Pre-ride P[...]

62 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1.Engine Oil Polaris Pre- mium 4 Syn- thetic 0W40 Add to proper level on dipstick. See page 37. Check level dai- ly . 2. Brake Fluid DOT 3 Only Maintain level between fill lines. See page 78. As required; change every two years or 200 hours 3. T ransmission Oil Polaris Pre-[...]

63 MAINTENANCE Lubrication Recommendations Operating Range Full 3. T ransmission 6. Front Prop Shaft (U-Joint) 9. Axle Cardan Front Drive (A WD Models) 5. Center Halfshaft (U Joint) 7. Propshaft Y oke Fill plug 4. Front Gear Case 10. Ball Joint 1 1. Front A-Arm Pivot Shaft Upper 8. 4 O ’ clock position 8. Demand Hubs[...]

64 MAINTENANCE Lubrication Recommendations 1 1 . Front A Arm Pivot Shaft Grease** ∆ Locate fitting on pivot shaft and grease with grease gun. Every 3 months or 50 hours 12. Swing Arm Bushings Grease** Locate fittings on swing arm and grease with grease gun. Monthly or at 20 hours 13. Upper Control Arms Grease** ∆ Locate fittings and grease Semi[...]

65 MAINTENANCE Lubrication Recommendations 13. Upper Control Arm 16. 17.[...]

66 MAINTENANCE W ARNING V ehicle operation with insuf ficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, acci- dent, and injury . Engine Oil In order for the engine to function properly , maintain the engine oil at t he proper level, and change the oil and oi l filter in accordance with t[...]

67 MAINTENANCE T ransmission Oil Changing Procedure 1. Locate and remove fill plug/ dipstick. 2. Remove transmission drain plug located on the bottom right hand side and drain the oil. Catch and discard used oil properly . 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Syn- thetic Gearcase Lubricant (PN 2871478) to full mark on the f[...]

68 MAINTENANCE Front Gearcase Lubrication Fill plug/Dipstick Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the front gearcase. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually . With the RANGER[...]

69 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut T orque Specifications Front Spindle Nut(s) Dealer Performed Service Front Wheel Nuts 15 Ft. Lbs. Center and Rear Hub Retaining Nut(s) 120 Ft. Lbs. Rear Wheel Nuts 15 Ft. Lbs. Front Wheel Hub Tig[...]

70 MAINTENANCE Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Air Filter Service It is recommended that the air filter be replaced yearly . When riding in ex- tremely dusty conditions replace- ment will be required more often. 1. Open the[...]

71 MAINTENANCE CAUTION: Operation of your vehicle without a breather filter can cause engine damage. Breather Filter and Hoses Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns. 1. Open hood and locate the airbox (1). 2. Follow right hand breather line out of the [...]

72 MAINTENANCE Coolant Level Inspection NOTE: Check the coolant level when the engine is cold (room or atmospheric temperature). 1. Situate the vehicle on level ground. 2. Check the coolant level through the coolant level gauge on the reserve tank lo- cated Behind the left hand en- gine compartment panel. The coolant level should be be- tween the F[...]

73 MAINTENANCE Spark Plugs  Proper electrode gap is .028 ″ /.7mm.  Spark plug torque is 17 ft. lbs. (2.3 kg/m).  Use NGK BKR5ES spark plugs.  Proper electrode gap is .025 ″ (.06 cm).  Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 1 1 ft. lbs (1.52 kg/m) for a new spark plug. Spark plug condition is indicative [...]

74 MAINTENANCE Spark Arrestor Th e exhaust pipe must be period- ically purged of accumulated car- bon as follows: 1. Remove the clean out plugs located on the bottom of the muf fler as shown above. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momen- tarily revving the engine sev- eral times.[...]

75 MAINTENANCE T ool Kit T o help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are:  screwdriver  open end wrench (8-10 mm)  open end wrench (12-14 mm)  tire pressure gauge  spark plug wrench and handle NOTE: Other tools are also necessary to perform main[...]

76 MAINTENANCE Throttle Pedal If the throttle pedal (1) has exces- sive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especial- ly at low engine speed. Also, the throttle may not open fully . If the throttle pedal has no play , the throttle may be hard to control, and the idle speed may be erratic. Ch[...]

77 MAINTENANCE Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following proce- dure covers the idle speed adjustment: Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory ,[...]

78 MAINTENANCE Front and Rear Brakes The front and brakes are hydraulic disc type brakes activated by the brake pedal. The following checks are recom- mended to keep the brake system in good operating condition. How often they need checking depends upon th e type of driving that has been done.  Inspect the level of the brake fluid before each ri[...]

79 MAINTENANCE Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system. The rear brake sys- tem is self adjusting and requires no maintenance other than periodic checks of the pads for wear . Wear Line  Pads should be changed when worn to 3/64 ″ (.1 cm) which is about[...]

80 MAINTENANCE Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Make sure the parking brake lever is functioning properly before each ride. Inspection:  Pull the parking brake lever up and to the rear .  After 8 to 12 clicks of lever travel, the vehicle should not roll while parked.  If the vehicle mo[...]

81 MAINTENANCE Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly . 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and remove the wheel. Wheel Installation 1. With the transmission in gear and the parking b[...]

82 MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below . Improper tire inflation may affect vehicle maneuverability . When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may a f fect vehicle handling. Tire T read Depth Always replace tires wh[...]

83 MAINTENANCE Seat Belts Make certain each seat belt functions properly before each ride. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound shows it is securely latched. Push the red button in the middle of the buckle to make sure it releases freely . Also check the belt webb[...]

84 MAINTENANCE Headlight Beam The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 25 ’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn the headlight switch to [...]

85 MAINTENANCE W ARNING Gasoline is highly flammable and explosive under certain conditions.  Always exercise extreme caution whenever handling gasoline.  Always refuel with the engine stopped and outdoors or in a well venti- lated area.  Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where [...]

86 MAINTENANCE Cleaning Y our RANGER Keeping your vehicle clean will not only improve its appearance but it can also ex- tend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. W ashing If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the w[...]

87 MAINTENANCE Storage If your vehicle is to be placed in extended or of f season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thor- oughly clean the vehicle. 2. Tu r n the fuel valve to “ of f ” and drain the carburetor . 3. Remove the spark plug and pour approximately one ounce o[...]

88 MAINTENANCE W ARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation and death. Bolt and Nut Tightening Tightness of the bolts, nuts and other fasteners should be checked by an autho- rized Polaris dealer in[...]

89 TROUBLESHOOTING Procedures Th e following information is provided to help you identify probable causes for ques- tions you may have about the operation of your vehicle. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT F AILS TO ST ART No Fuel W ater in Fuel Spark Plug Fuel V alve Off Drain System No Spark to [...]

90 SPECIFICA TIONS Gross V ehicle Weight 3020 lbs. Fuel Capacity 9.5 Gallons C T owing Capacity 1500 lbs. C A Maximum Cargo Box Load 1000 lbs. A P A Overall Length 1 13 in. A C Overall Width 58 in. (Tires) 60 ″ (Cargo Box) C I T Overall Height 75 in. T I Wheelbase 81 in. I E S Ground Clearance 8.5 in. S Dry W eight 1520 lbs. Cargo Box (L x W x H)[...]

91 SPECIFICA TIONS D Driving System T ype PVT D R Shift T y pe Single Lever/Center Console R I V Gear Reduction - Low 24.16:1 V E Gear Reduction - Reverse 18.67:1 E T Gear Reduction - High 1 1.97:1 T R Drive Ratio - Front: 2:1 R A I Drive Ratio - Final 3.5:1 I N Drive Ratio - Center 1:3.5 N Front Final Gear Case Oil Capacity 32 ounces T I Tire Size[...]

92 W ARRANTY[...]

93 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a SIX MONTH LIMITED W ARRANTY on all components of the Polaris RANGER against defects in material or workmanship. This warranty cov- ers the parts and labor charges for repair or replacement of defective parts which are covered b[...]

94 W ARRANTY W ARRANTY OR ANY OTHER CONTRACT , NEGLIGENCE, OR OTHER TOR T OR OTHERWISE. Some states do not permit the exclusion or limitation of inciden- tal or consequential damages or implied warranties, so the above limitations or ex - clusions may not apply to you if inconsistent with controlling state law . AL L IMPLIED W ARRANTIES (INCLUDING [...]

INDEX 95 Air Cleaner 70 . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 31 . . . . . . . . . . . . . . . . . . . Backing Up 54 . . . . . . . . . . . . . . . . . . . . . . Battery Installation 58 . . . . . . . . . . . . . . . . Battery Maintenance 5 7 . . . . . . . . . . . . . . Battery Removal 58 . . . . . . . . . . . . . . . . . . Brak[...]