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Table of Contents
Related Manuals for Polaris 2005 99 Ranger
Summary of Contents for Polaris 2005 99 Ranger
- Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
- Page 4 All information in this manual is based upon the latest product data and specifica- tions available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or ex- planations.
- Page 5 Do not turn at excessive speed. S Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate this vehicle on hills too steep for the vehicle or for your abilities.
- Page 6 S Always shut off the engine before refueling. Make sure the area is well venti- lated and free of any source of flame or sparks. Gasoline is very flammable. See page 24 for refueling instructions. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.
- Page 7 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 speed or pow- er of the vehicle;...
- Page 8 Registered Owners Your 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. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its prod- ucts.
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Page 9: Table Of Contents
CONTENTS UNDERSTANDING WARNINGS ......SAFETY WARNING AND OPERATION DECALS LABEL LOCATIONS ........DAILY PRE-RIDE INSPECTION . -
Page 10: Understanding Warnings
UNDERSTANDING WARNINGS 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. -
Page 11: Safety Warning And Operation Decals
SAFETY WARNING AND OPERATION DECALS WARNING VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATH This cab frame is not designed or intended to provide rollover protection in the event of vehicle overturning. See Owner’s Manual. l Riders can be thrown off. This can cause serious in- jury or death. - Page 12 SAFETY WARNING AND OPERATION DECALS HEADLAMPS ARE NOT SEALED. DO NOT SUBMERGE OR APPLY WATER PRESSURE DIRECTLY ONTO SERVICE OPENING. Recoil handle must be firmly seated to prevent water entry. Drain starter motor if water enters. See owner’s manual. 7075741 WARNING/AVERTISSEMENT This vehicle is designed for operator and “ONE”...
- Page 13 SAFETY WARNING AND OPERATION DECALS 7077683 Text found below OPERATOR/LOAD DISTRIBUTION WARNINGS VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSS OF CONTROL AND RESULT IN SEVERE INJURY OR DEATH. MAKE STARTS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTH MANNER so as not to shift the load or overturn the vehicle.
- Page 14 SAFETY WARNING AND OPERATION DECALS THE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING IN A LOADED CONDITION on rough or hilly terrain. When climbing hills always hav- ing the cargo in the rear box securely fastened and located as far forward in the box as possible.
- Page 15 SAFETY WARNING AND OPERATION DECALS Text found below READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER 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. D This vehicle REQUIRES SPECIAL RIDING SKILLS due to its handling.
- Page 16 SAFETY WARNING AND OPERATION DECALS D OPERATION 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 ∠...
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Page 17: Label Locations
LABEL LOCATION Warning (General) Warning (Vehicle roll-over) Warning (Load Distribution) Warning (Cargo Bed) Tire Pressure Towing Information... -
Page 18: Daily Pre-Ride Inspection
DAILY 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. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your RANGER before riding following the checklist care- fully. -
Page 19: Operation Warnings
HOW TO AVOID THE HAZARD No one without a valid driver’s license should operate a Polaris RANGER. - Page 20 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN This vehicle’s tires are designed for off-road use only; not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways, parking lots and streets.
- Page 21 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs. WHAT 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 TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this vehicle.
- Page 22 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your RANGER each time you use it to make sure it is in safe operating condition.
- Page 23 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip- pery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ve-...
- Page 24 OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID 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.
- Page 25 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
- Page 26 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner’s Manual.
- Page 27 HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris In- dustries Inc. or equivalent components designed for use on this vehicle; and should be installed and used according to instructions.
- Page 28 OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.
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Page 29: Vehicle Identification Numbers
VEHICLE IDENTIFICATION NUMBERS Important: Record these numbers from your vehicle in the spaces provided. 1. Frame VIN: 2. Vehicle Model Number: 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. - Page 30 CONTROL PARTS 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.
- Page 31 CONTROL PARTS AND FUNCTIONS Parking Brake Lever The 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. To release, push in and hold the knob on the end of the lever and push the lever all the way down.
- Page 32 CONTROL PARTS AND FUNCTIONS Seat Belts The vehicle is equipped with lap-style seat belts for the operator and passenger. WARNING 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 vehicle.
- Page 33 Switch back immedi- ately to gasoline which does not contain alcohol if you experience any operating irregularities. Any deterioration of fuel system com- ponents or degradation of perfor- mance resulting from the use of gasohol will not be covered by Polaris’ Warranty.
- Page 34 CONTROL PARTS AND FUNCTIONS WARNING Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well venti- lated area. D Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
- Page 35 CONTROL PARTS AND FUNCTIONS WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm. 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).
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Page 36: Control And Parts Functions
CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Left View Cab Frame Cab Frame Hand Hold Dashboard Steering Wheel Gear Shift Lever Seat Cargo Box Seat Belts Parking Brake 10. Engine Compartment Access Panel 11. Hood Latches (attached to hood; left and right sides under dash) - Page 37 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Front View 12. Headlights 13. Air Box (under hood) 14. Battery (under hood) 15. Radiator (under hood) 16. Front Bumper/Brush Guard...
- Page 38 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Rear View 17. Tail Gate Latches (Top and Bottom) 18. Tail Gate 19. Muffler (Spark Arrester) 20. Trailer Hitch Receiver 21. Taillight...
- Page 39 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Instrument Panel Choke Knob Ignition Switch Hour Meter Passenger Warning Decal Neutral Indicator Light Reverse Indicator Light Brake Light Coolant Temperature Warning Light Fuel Gauge 10. 12V Accessory Plug 11. Fog/High Beam Light Switch 12.
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Page 40: Demand 6 Drive
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 “off”... - Page 41 CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation The 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 in heavy pulling situations to extend belt life.
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Page 42: Disengaging Wheel Hubs
D Routine maintenance is the responsibility of the owner. Always fol- low recommended maintenance procedures. See your dealer! D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation. - Page 43 NOTE: Some coolant level drop on new machines is normal as the system is purg- ing itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water.
- Page 44 Failure to properly maintain this important area can result in premature wear or pos- sible failure of the engine com- ponents. Always use Polaris Recoil 0W-40 oil. Drain Engine Access Panel Removal and Installation...
- Page 45 Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. IMPORTANT: Al- ways follow the manufacturer’s mixing recommendations for the freeze protection...
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Page 46: Oil System
Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more fre- quently if Polaris Premium 4 is not used. You will also need to follow the manufac- turers recommendations for ambient temperature operation. - Page 47 NOTE: Severe use cold weather riding is all riding below 10° F, and riding between 10° F and 30°F when most trips are slow speed and less than 5 miles. Be sure to change the oil filter whenever changing oil (Polaris PN 3084963).
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Page 48: Control And Parts Functions
CONTROL AND PARTS 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. -
Page 49: Starting The Engine
STARTING 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 WARNING Do not start or operate this vehicle with sticking or improperly operating... - Page 50 STARTING 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.
- Page 51 STARTING THE ENGINE Procedure for Starting a Warm Engine Warm 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.
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Page 52: Recoil Starter
STARTING THE ENGINE 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. -
Page 53: Vehicle Break In Period
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 efficient performance and longer life for the engine. -
Page 54: Carrying 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) RANGER - 1500 lbs. (681 kg) Dumping the Cargo Box 1. -
Page 55: Operation Safety
OPERATING 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. The cargo box dump latch must be securely latched before loading and operat- ing. - Page 56 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.
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Page 57: Riding On Slippery Surfaces
OPERATING 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. - Page 58 Operating on Hills WARNING Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur. D Avoid crossing the side of a steep hill if possible. D Use extreme care when operating your RANGER in hilly terrain. Whenever descending a hill always: 1.
- Page 59 OPERATING SAFETY indicates a potential hazard which WARNING could result in serious injury or death. WARNING Braking and handling are greatly affected whenever operating in hilly ter- rain. Loss of vehicle control or overturning of the vehicle could occur. D Avoid climbing steep hills (15_ maximum). D Use extreme care when operating your vehicle in hilly terrain.
- Page 60 OPERATING SAFETY WARNING 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.
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Page 61: Crossing Streams
OPERATING SAFETY Crossing Streams Your 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. -
Page 62: Trail Obstacles
Trail 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. WARNING Hidden or unseen hazards on the trail can be dangerous. -
Page 63: Backing Up
OPERATING 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. - Page 64 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.
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Page 65: Noise Emission Control System Regulation
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING 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 vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed... -
Page 66: Battery
Battery CAUTION Whenever removing the battery, discon- nect the negative (black) cable first. When reinstalling the battery, connect the nega- tive (black) cable last. Maintain Replenishing the Battery Fluid between A poorly maintained battery will deteriorate upper and rapidly. Check the battery fluid level often. lower level The fluid level should be kept between the marks... -
Page 67: Battery Removal
BATTERY 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. -
Page 68: Maintenance
Inspect, clean, lubricate, adjust or replace parts as necessary. CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair. - Page 69 MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Frequency Odometer Fuel System 100 hours 12 months Fuel Filter 100 hrs 12 months Carburetor Float Bowl 50 hrs 6 months Idle Speed As Required As Required Throttle Cable 50 hrs 6 months Choke (Enricher) Cable 50 hrs 6 months...
- Page 70 Pre-ride CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair. " More often under severe use, such as dirty or wet conditions...
- Page 71 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method 1.Engine Oil Polaris Pre- Add to proper level on dipstick. mium 4 Syn- See page 37. thetic 0W40 2. Brake Fluid DOT 3 Only Maintain level between fill lines. See page 78. 3. Transmission Polaris Pre- Add to FULL level on dipstick.
- Page 72 Lubrication Recommendations 4. Front Gear Case 3. Transmission Full Operating Range 6. Front Prop Shaft (U-Joint) 9. Axle Cardan Front Drive (AWD Models) Upper 11. Front A-Arm Pivot Shaft 10. Ball Joint MAINTENANCE Fill plug 7. Propshaft Yoke 5. Center Halfshaft (U Joint) 8.
- Page 73 * More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 500 miles, or after submerging in water or before long periods of storage or after pressure washing.
- Page 74 MAINTENANCE Lubrication Recommendations 13. Upper Control...
- Page 75 (2). Remove fill plug dipstick (3) by pulling upward and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lu- bricant to use is Polaris Premium Syn- thetic Gearcase Lubricant 2871478).
- Page 76 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 Full the fill plug/dipstick. 5. Check for leaks.
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Page 77: Front Gearcase Lubrication
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. - Page 78 Retaining Nut(s) Rear Wheel Nuts Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op- erations. Service work must be performed by your authorized Polaris dealer. MAINTENANCE 15 Ft. Lbs. 120 Ft. Lbs. 15 Ft. Lbs.
- Page 79 MAINTENANCE Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjuster in Rear Spring the direction required to increase or Adjustment 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.
- Page 80 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 WARNING has been run. The exhaust system becomes very hot and can cause severe burns. Open hood and locate the airbox (1).
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Page 81: Coolant Level Inspection
F (Full) mark. Install the cap. NOTE: Polaris recommends the use of Polaris Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum compat- ible anti-freeze/coolant and dis- tilled water. IMPORTANT: Polaris Premium 60/40 is already pre- mixed and ready to use. -
Page 82: Spark Plugs
MAINTENANCE Spark Plugs D Proper electrode gap is .028″/.7mm. D Spark plug torque is 17 ft. lbs. (2.3 kg/m). D Use NGK BKR5ES spark plugs. D Proper electrode gap is .025″ (.06 cm). D Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs (1.52 kg/m) for a new spark plug. -
Page 83: Spark Arrestor
MAINTENANCE Spark Arrestor The 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 muffler 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-... - Page 84 D Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your dealer! D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation.
- Page 85 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.
- Page 86 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, and all other conditions are favorable, the carburetor can be adjusted as follows: 1.
- Page 87 Do not operate the vehicle under these conditions. Have the brake system ser- viced by an authorized Polaris dealer immedi- ately. D Check friction pads for wear, damage and looseness.
- Page 88 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 D Pads should be changed when worn to 3/64″...
- Page 89 D There should be 0.8 - 1.0 in (20 - 25 mm) of free play. D If there is excessive free play or strange noises, or the steering feels rough or “catchy,” have the steering system checked by an authorized Polaris deal-...
- Page 90 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.
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Page 91: Tire Inspection
MAINTENANCE WARNING Operating your vehicle with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. - Page 92 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 webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked or replaced by an authorized Polaris dealer...
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Page 93: Indicator Lamp Replacement
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. - Page 94 WARNING Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well venti- lated area. D Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
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Page 95: Cleaning Your Ranger
Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a cham- ois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement. - Page 96 Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thor- oughly clean the vehicle. 2. Turn the fuel valve to “off” and drain the carburetor.
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Page 97: Maintenance
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 accordance with the Periodic Maintenance Chart. -
Page 98: Troubleshooting
Procedures The 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 FAILS TO START... -
Page 99: Specifications
SPECIFICATIONS Gross Vehicle Weight 3020 lbs. Fuel Capacity 9.5 Gallons Towing Capacity 1500 lbs. Maximum Cargo Box Load 1000 lbs. Overall Length 113 in. Overall Width 58 in. (Tires) 60″ (Cargo Box) Overall Height 75 in. Wheelbase 81 in. Ground Clearance 8.5 in. -
Page 100: Specifications
Driving System Type Shift Type Single Lever/Center Console Gear Reduction - Low 24.16:1 Gear Reduction - Reverse 18.67:1 Gear Reduction - High 11.97:1 Drive Ratio - Front: Drive Ratio - Final 3.5:1 Drive Ratio - Center 1:3.5 Front Final Gear Case Oil Capacity 32 ounces Tire Size - Front 25 x 10 - 12 (12 psi MAX) -
Page 101: Warranty
WARRANTY... - Page 102 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, nor- mal wear and tear, abuse or improper handling. This warranty also does not cover...
- Page 103 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the War- ranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
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Page 104: Index
INDEX Air Cleaner ..... . Maintenance Schedule All Wheel Drive ....Noise Control System Backing Up .