Polaris 2016 RANGER EV Li-Ion Owner's Manual
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Polaris 2016 RANGER EV Li-Ion Owner's Manual

Polaris 2016 RANGER EV Li-Ion Owner's Manual

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RANGER® EV Li-Ion
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 2016 RANGER EV Li-Ion

  • Page 1 RANGER® EV Li-Ion Owner’s Manual for Maintenance and Safety...
  • Page 2 Failure to follow the safety precautions could result in serious injury or death. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS® and RANGER® are trademarks of POLARIS Industries Inc. Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Specifications ........68 POLARIS Products........70 Troubleshooting .

  • Page 6: Introduction

    INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
  • Page 7 Failure to follow the warnings contained in this manual can result in severe injury or death. Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. A key can be duplicated only by ordering a key blank (using your key number) and mating it with one of your existing keys. The key switch must be replaced if all keys are lost.
  • Page 9 INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

  • Page 10: Safety

    Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 11 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 12 • Connect battery charger to properly rated electrical receptacle with GFCI. • Refer to Owner’s Manual or contact your local POLARIS dealer with any questions. TO MAXIMIZE BATTERY LIFE • For storage (longer than one month), the vehicle should be charged to 50-70% SOC.
  • Page 13 SAFETY Safety Labels and Locations Proper Use Warning (7179978) Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license.
  • Page 14 SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning (7182498) WARNING Passenger/Tire Fuel Transport Pressure Warning • Passengers can be thrown off. This can cause Warning serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

  • Page 15: Operator Safety

    • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.

  • Page 16: Equipment Modifications

    Never install any accessory that grounds to the vehicle chassis. The chassis is a floating ground to protect against electrical short circuits and hazards. Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

  • Page 17: Age Restrictions

    SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.

  • Page 18: Operating A Damaged Vehicle

    SAFETY Operator Safety Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your RANGER to make sure it's in safe operating condition.

  • Page 19: Operating On Pavement

    SAFETY Operator Safety Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement.

  • Page 20: Improper Hill Climbing

    SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures for climbing hills as described in this owner's manual. See page 38. Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in the owner's manual.
  • Page 21 • All battery and electrical service must be performed only by an authorized service facility. Your POLARIS dealer can assist. • Make sure the vehicle is properly immobilized before beginning any maintenance. • Always block the chassis securely before working under the vehicle.

  • Page 22: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Cab Frame Cargo Cargo Box Release Lever Hip Bars Seat Belts Front Bumper/Brush Guard Tailgate Latch Releases Tailgate Taillight Receiver Hitch...

  • Page 23: Auxiliary Outlet

    FEATURES AND CONTROLS Console 12V Auxiliary Key/Light Outlet Switch Switch Drive Mode Direction Switch Selector Key/Light Switch Turn the key to the LIGHTS ON position to operate with the lights on. Turn the key to the LIGHTS OFF position to operate with the lights off.

  • Page 24: Drive Mode Switch

    FEATURES AND CONTROLS Console Drive Mode Switch CAUTION! Changing the drive mode switch position while driving High could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure. Maximum High Mode Range Press the top of the switch to select high mode. Use high mode for most trail-riding conditions.

  • Page 25: Awd Switch

    FEATURES AND CONTROLS Console Direction Selector Switch When the direction selector is in the center position, the vehicle is in neutral. The vehicle will not move if the Forward accelerator pedal is depressed. Push the top of the switch to choose forward operation. Push the bottom of the switch to choose reverse operation.

  • Page 26: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components. Wash the vehicle by hand Speedometer Indicator or with a garden hose using mild soap. Lamps Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens.

  • Page 27: Rider Information Center

    When both the chassis fault lamp and the fault indicator (wrench symbol) illuminate, use the mode button to toggle through fault codes or warning messages in the display. Your authorized POLARIS dealer can provide code details and diagnosis. State of Charge State of Charge This indicator illuminates when the key is turned on.
  • Page 28 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Mode This area will display clock, odometer, trip meter, state of charge (SOC), range meter, efficiency rate (EFF) or any existing fault MODE codes or warning messages. Button The display can be changed to show either standard or metric units of measurement for each of the following settings.
  • Page 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Mode Odometer The odometer displays the distance traveled by the vehicle since manufacture. Trip Meter The trip meter displays distance traveled since the last reset of the trip meter. To reset, toggle to the trip meter display.
  • Page 30 • Avoid disconnecting and connecting battery cables. All battery and electrical service must be performed only by an authorized service facility. Your POLARIS dealer can assist. • Always keep battery terminals and connections clean and free of corrosion. See page 63.

  • Page 31: Charger Operation

    FEATURES AND CONTROLS Batteries Ambient Temperature Implications on Batteries 1. Batteries discharge when left uncharged. They can discharge with the key off, and much faster if the key is left on. 2. Batteries can become too cold to function at low ambient temperatures. See page 30. 3.
  • Page 32 FEATURES AND CONTROLS Batteries Battery Operating Temperature The vehicle will not operate if one or more batteries has an internal temperature below 14° F (-10° C). When not in use, park the vehicle and connect the battery charger. See page 64. When the vehicle is connected to the charger, batteries are maintained at full performance operating temperature in addition to receiving a full charge.

  • Page 33: Main Power Connector

    To disconnect, unplug the connector. After servicing the vehicle, the main power connector should be the last connection to be made. Main Power Connector WARNING! All battery and electrical service must be performed only by an authorized service facility. Your POLARIS dealer can assist.

  • Page 34: Charging Cord

    FEATURES AND CONTROLS Auxiliary 12-Volt Terminal Board The 12-volt terminal board is located under the hood. It contains constant 12-volt, switched 12-volt and ground terminals that can be used to power auxiliary lights and accessories. The terminals are limited to 10 amps. Charging Cord The charging cord is located under the hood on the right side of the vehicle.

  • Page 35: Accelerator Pedal

    41-42. Roll-Over Protection System (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect ROPS the ROPS if it ever becomes damaged in any Label way.

  • Page 36: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are Latch Plate secured for all riders before operating. The center of the seat is NOT equipped with a seat belt.

  • Page 37: Operation

    Inspect, ensure tightness Accelerator Ensure proper operation Indicator lights/switches Ensure operation Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat belts Check length of belt for damage, check latches for proper...

  • Page 38: Driving Procedure

    OPERATION Driving Procedure 1. Disconnect the charging cable. 2. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 3. Sit in the driver's seat and fasten the seat belt. 4. Apply the brakes. If the vehicle is not connected to the charger while parked in temperatures below 14°...

  • Page 39: Driving On Slippery Surfaces

    OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.

  • Page 40: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

  • Page 41: Driving Through Water

    OPERATION Driving Through Water Your POLARIS vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards.

  • Page 42: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 43: Hauling Cargo

    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.

  • Page 44: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 41. Towing a trailer increases braking distance.

  • Page 45: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not Release attempt to dump or unload the vehicle while parked on Lever an incline. 2. Apply the brakes. 3. Set the park brake. 4.

  • Page 46: Locking The Differential

    OPERATION All Wheel Drive (AWD) Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off. The AWD switch may be turned on or off while the vehicle is moving.

  • Page 47: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

  • Page 48: Winch Safety Precautions

    WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15.

  • Page 49: Winch Operation

    WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 50 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 51 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object.
  • Page 52 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 53: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 54 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 55: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 56: Maintenance

    D Have an authorized POLARIS dealer or other qualified person perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.

  • Page 57: Periodic Maintenance Chart

    Adjust as needed Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 54, or more often under severe use, such as wet or dusty conditions.

  • Page 58: Gearcase Specification Chart

    Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 70 for the part numbers of POLARIS products. Fill Plug Drain Plug Oil Check The fill plug is located at the right rear of the vehicle.

  • Page 59: Front Gearcase

    Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 56 for recommended lubricants, capacities and torque specifications. See page 70 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the left side of the front gearcase.

  • Page 60: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 32. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 61: Steering Wheel Inspection

    3. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer. Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation.

  • Page 62: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 8"(20 cm) 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

  • Page 63: Tire Tread Depth

    Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use POLARIS-approved size and type of tires for this vehicle when replacing tires. Tire Tread Depth Always replace tires when tread depth is 1/8"...

  • Page 64: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist. 2. Attach the wheel nuts and washers and finger tighten.

  • Page 65: Battery Replacement

    WARNING! Handling batteries and electrical components improperly can result in serious injury or death. Do not attempt to remove batteries or battery cables. All battery and electrical service must be performed only by an authorized service facility. Your POLARIS dealer can assist. Battery Access To access the batteries, remove the seat.

  • Page 66: Battery Charging

    MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger. See page 64. When the vehicle is connected to the charger, batteries are maintained at full performance operating temperature in addition to receiving a full charge. If the vehicle is not connected to the charger while parked in cold weather, battery temperatures may drop below 14°...

  • Page 67: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 68: Polishing The Vehicle

    MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 69: Storing The Vehicle

    MAINTENANCE Cleaning and Storage Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 65. 2. Store the vehicle out of the sun in a cool, dry place. 3.

  • Page 70: Specifications

    SPECIFICATIONS RANGER EV Li-Ion Dimensions Curb Weight 1288 lbs. (584 kg) Test GVW - Rollover Protection 2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53 System (ROPS) Ground Clearance 10 in. (25.4 cm) Length 108 in. (274.3 cm) Width 56.5 in. (143.5 cm) Height 73 in.
  • Page 71 SPECIFICATIONS RANGER EV Li-Ion Brake System Brakes 4-Wheel hydraulic disc w/dual bore front calipers Park Brake Dash-mounted lever-activated mechanical park brake Suspension Front suspension McPherson Strut w/9 in. (22.7 cm) of travel Rear suspension Dual A-Arm w/9 in. (22.9 cm) travel Tires 25x9-12 Carlisle All Trail II Tire pressure...

  • Page 72: Polaris Products

    POLARIS PRODUCTS Part Number Description Gearcase Lubricants 2876160 ATV Angle Drive Fluid (qt./.95 l) 2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l) 2877922 Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (2.5 gal./9.5 l) Grease / Specialized Lubricants 2871312...

  • Page 73: Warranty

    Any capacity/range reduction-based claim must be confirmed by an authorized dealer and approved by POLARIS to be eligible for coverage. In addition to the WARRANTY COVERAGE EXCLUSIONS listed below, the battery warranty also excludes failure, damage or capacity loss to the batteries caused by neglect, lack of charging or not following the recommended maintenance schedule outlined in the Owner’s Manual.
  • Page 74 The exclusive remedy for breach of this warranty shall be, at POLARIS MOTORCYCLES’s option, repair or replacement of any defective materials, components, or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 75 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 76 SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location.

  • Page 77: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 78 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 79: Index

    INDEX Accelerator Pedal ......33 Equipment Modifications ....14 All Wheel Drive .

  • Page 80: Oil Change

    Vehicle Will Not Operate ....70 Polaris Products ......70 Polishing the Vehicle.
  • Page 81 12 or who cannot comfortably reach the floor and hand holds. • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.

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