Polaris Ranger 1000 Diesel Owner's Manual
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Polaris Ranger 1000 Diesel Owner's Manual

Polaris Ranger 1000 Diesel Owner's Manual

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2018
OWNER'S MANUAL
RANGER® 1000 Diesel
RANGER® 1000 Diesel EPS
RANGER CREW® 1000 Diesel

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Summary of Contents for Polaris Ranger 1000 Diesel

  • Page 1 2018 OWNER’S MANUAL RANGER® 1000 Diesel RANGER® 1000 Diesel EPS RANGER CREW® 1000 Diesel...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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. • Snowmobiles •...
  • Page 4 POLARIS®, RANGER® and RANGER CREW® are trademarks of POLARIS Industries Inc. Copyright 2017 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 ........100 POLARIS Products....... . . 104 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

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition 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

    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: Safe Riding Gear

    Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs.
  • Page 12 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 13 SAFETY Safety Labels and Locations Fuel Transport Warning This label can be found in the rear cargo box. WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. 7186122 Payload Warning/Shift Caution WARNING...

  • Page 14: Clutch Cover Warning

    Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner’s manual or see authorized POLARIS dealer. 7177469 Clutch Cover Warning...

  • Page 15: Operator Safety

    SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described.
  • Page 16 • 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 17: Equipment Modifications

    POLARIS at 1-800-342-3764. Equipment Modifications 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 18: 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 19 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle.

  • Page 20: Exposure To Exhaust

    SAFETY Operator Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

  • Page 21: Turning Improperly

    SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

  • Page 22: Operating On Slippery Terrain

    SAFETY Operator Safety Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly).

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab nets (or doors).

  • Page 24: Gear Selector

    Always shift when the vehicle is stationary and the engine is at idle. Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. Using Low Range Always shift into low gear for any of the following conditions.

  • Page 25: Mode Button

    FEATURES AND CONTROLS Switches Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.

  • Page 26: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Throttle Depress the brake pedal to slow or stop the vehicle. Apply Brake Pedal the brakes while starting the engine. Pedal Throttle Pedal Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.
  • Page 27 FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery. Pull the rear edge of a seat upward to release the latch pins from the grommets.

  • Page 28: Fuel Cap

    FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver’s seat. Use only the recommended diesel fuel. See page 37. Hood Latches Latches Remove the hood to access the coolant overflow bottle, the radiator cap and the headlight adjustment screws.

  • Page 29: Trailer Hitch Bracket

    Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.
  • Page 30 Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer. Securing a Net Latch 1.

  • Page 31: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER.

  • Page 32: Instrument Cluster

    If this occurs, your POLARIS dealer can provide proper diagnosis. 1. Vehicle Speed (Speedometer) Display - Analog display of vehicle speed in MPH or km/h.
  • Page 33 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode. 4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the high beam position.

  • Page 34: Information Display Area

    FEATURES AND CONTROLS Instrument Cluster Information Display Area The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock. Units of Measurement Distance Miles (MPH)
  • Page 35 FEATURES AND CONTROLS Instrument Cluster Information Display Area Tachometer (RPM) Engine RPM can be displayed digitally. Engine Temperature Engine temperature can be displayed in °F or °C. Refer to “Units of Measurement” to change the format. Clock The clock displays the time in a 12-hour or 24-hour format. Refer to “Units of Measurement”...
  • Page 36 FEATURES AND CONTROLS Instrument Cluster Information Display Area Programmable Service Interval The initial factory service interval setting is 50 hours. Each time the engine is started, the engine hours are subtracted from the service interval hours. When the service interval reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started.

  • Page 37: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER is the first 50 hours of operation.
  • Page 38 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel...

  • Page 39: Fuel Recommendations

    ONLY the recommended diesel fuels. Use only CLEAN diesel fuel. POLARIS recommends the following diesel fuels for use in this vehicle: • Ultra Low Sulfur #2 • #1 Diesel Fuel containing no more than 20% bio-diesel (see page 38) See page 40 for cold weather fuel blend recommendations.
  • Page 40 OPERATION Fuel Recommendations Bio-Diesel Fuels In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.
  • Page 41 Fuel Recommendations Bio-Diesel Fuels B21 To B100 Bio-diesel Fuel Blend Usage B21 to B100 bio-diesel is not approved for this POLARIS application. Approved Engines Only the KOHLER KDW engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applications.

  • Page 42: Cold Weather Operation

    OPERATION Fuel Recommendations Refueling The fuel tank filler cap is located on the right side of the vehicle near the passenger seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill. Cold Weather Operation Cold weather operation can result in fuel gelling if the incorrect fuel type is used.
  • Page 43 OPERATION Cold Weather Operation Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle. See page 38. Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle: •...
  • Page 44 • If the ambient temperature exceeds +104° F (+40° C), the engine may overheat and cause the engine oil to break down. • If the ambient temperature is between +5° F (-15° C) and -25° F (-32° C), POLARIS recommends the use of a block heater. See page 40.

  • Page 45: Starting The Engine

    OPERATION Starting the Engine NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Before operating this vehicle in cold weather, review the cold weather operation information beginning on page 40. Always wait for the glow plug indicator light to turn off before cranking the engine.

  • Page 46: Driving Procedure

    OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection. See page 36. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets (or doors) while riding in this vehicle. 5.

  • Page 47: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 36. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

  • Page 48: 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 49: 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 50: Driving Through Water

    OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your POLARIS dealer can provide this service.

  • Page 51: 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 52: Parking The Vehicle

    OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 53: 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 54: 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. When transporting heavy loads and/or when towing, always operate the vehicle in low gear and have ADC activated (if equipped).

  • Page 55: Dumping The Cargo Box

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

  • Page 56: Engaging Awd

    OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. See page 31. Differential Lock When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction.

  • Page 57: Locking The Differential

    OPERATION All Wheel Drive (AWD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

  • Page 58: 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 59: 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 60: 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 61 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 62 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 63: Winch Cable Care

    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 64 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 65: 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 66: Emission Control Systems

    Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 67: 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 68: Periodic Maintenance Chart

    ? Front Suspension 50 H 500 (800) Lubricate ? Rear Suspension 50 H 500 (800) Lubricate ? Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.
  • Page 69 Auxiliary brake (if equipped) Inspect daily; adjust as needed Headlight aim 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.

  • Page 70: Lubrication Recommendations

    Periodic Maintenance Chart. Oil Recommendations POLARIS recommends the use of semi-synthetic or full synthetic POLARIS Diesel Oil (SAE 15W-40) or equivalent oil for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation. See the chart below.

  • Page 71: Oil Check

    MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components.

  • Page 72: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Always change the oil filter whenever changing oil. The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole in the skid plate under the crankcase (see next page).
  • Page 73 MAINTENANCE Engine Oil Oil and Filter Change 12. Reinstall the drain plug. Torque the drain plug to 29.5 ft. lbs. (40 Nm). 13. Remove the oil fill cap and add 3 quarts (2.8 l) of recommended oil. Reinstall the fill cap.

  • Page 74: Gearcase Specification Chart

    65. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 104 for the part numbers of POLARIS products. Gearcase Oil Check The level check/fill plug is located on the rear of the gearcase.
  • Page 75 Maintenance Chart beginning on page 65. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 104 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

  • Page 76: Cooling System

    Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle. Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 104 for the part numbers of POLARIS products.
  • Page 77 But if the overflow bottle has run dry, the level in the radiator should also be inspected. 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
  • Page 78 • See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 79 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 80 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 8. Rotate the driven clutch by hand until the belt is completely off. Step 8 9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it.

  • Page 81: Pvt Drying

    5. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. Drain Plug 6. Test for belt slippage. If the belt slips, repeat the process. 7. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.

  • Page 82: Vehicle Immersion

    5. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 6. If water has been ingested into the PVT follow the procedure on page 79 for drying.

  • Page 83: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the 5 Latches intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the air filter more frequently if the vehicle is operated in wet or dusty conditions or at high Filter throttle for extended periods.

  • Page 84: Spark Arrester

    MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures ° can reach 1000 F.
  • Page 85 MAINTENANCE Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 65. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle.
  • Page 86 MAINTENANCE Fuel Filter/Water Separator The fuel filter/water separator is located under the seat on the right side of the vehicle, between the engine and fuel tank. Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 65.

  • Page 87: Throttle System

    Freeplay should be 1/16 to 1/8 inches (1.6-3.2 mm). Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service person for adjustment. Throttle Freeplay Adjustment 1. Unlatch the cargo box.

  • Page 88: Brake Fluid

    MAINTENANCE Brakes WARNING Do not perform maintenance immediately after the vehicle has been operated, as the brake system may become very hot. Serious burns could result from contact with hot brake components. Allow components to cool before proceeding. • Wear eye protection and gloves. Brake Fluid Inspect the brake system routinely.

  • Page 89: Brake Inspection

    3. Lightly turn the steering wheel left and right. There should be 0.8”-1.0” (20-25 mm) of freeplay. 4. 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.

  • Page 90: Suspension Adjustments

    MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting positions. 2. Reposition the shocks to the outside mounting holes. 3. Reinstall the shock mounting bolts. Torque to 40 ft. lbs. (54.2 Nm). Outside Mounting Position Inside Mounting Position...

  • Page 91: 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 92: 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. 3. Attach the wheel nuts and washers and finger tighten.

  • Page 93: Headlight Lamp Replacement

    MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced.

  • Page 94: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 95 The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.

  • Page 96: Battery Removal

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 95. POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

  • Page 97: Battery Charging

    MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.

  • Page 98: 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 99: Polishing The Vehicle

    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. • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 100 • Coolant (test strength/fill) Storage Area/Covers Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 101: Removal From Storage

    2. Fill the fuel tank with fuel. 3. Check all the points listed in the Daily Pre-Ride Inspection section on page 36. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 4. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page Transporting the RANGER Follow these procedures when transporting the vehicle.

  • Page 102: Specifications

    SPECIFICATIONS RANGER Diesel Maximum Weight Capacity 1500 lbs. (681 kg) (including operator, passenger, cargo, accessories) Dry Weight 1430 lbs. (649 kg) Test GVW - Rollover Protection 3400 lbs. (1542 kg) per OSHA 29 CFR 1928.53 System (ROPS) Fuel Capacity 10 gal. (37.8 l) Engine Oil Capacity 3 qts.
  • Page 103 Tire Pressure - Rear 12 psi (83 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.
  • Page 104 SPECIFICATIONS RANGER CREW Diesel Maximum Weight Capacity 1750 lbs. (795 kg) (including operator, passengers, cargo, accessories) Dry Weight 1690 lbs. (767 kg) Test GVW - Rollover Protection 3700 lbs. (1678 kg) per OSHA 29 CFR 1928.53 System (ROPS) Fuel Capacity 10 gal.
  • Page 105 Tire Pressure - Rear 16 psi (110 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.

  • Page 106: Polaris Products

    2871460 Premium Starter Grease 2871515 U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 107: Troubleshooting

    Poor engine performance Check for clogged air filter, clogged fuel filter, water in the fuel or foreign material in fuel tank or fuel lines. Your POLARIS dealer can assist. Slippage from failure to warm up Always warm up the belt by operating below 30 MPH for one mile (5 belt miles or more when temperature is below freezing).
  • Page 108 Drain the fuel system and refuel, replace fuel filter/ water separator Old or non-recommended fuel Replace with fresh recommended fuel Water or fuel in crankcase Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure Your POLARIS dealer can assist.
  • Page 109 Other mechanical failure Your POLARIS dealer can assist. Out of fuel Refuel Low battery voltage Recharge the battery to 12.8 VDC Overheated engine Clean radiator screen and core, clean engine exterior, operate at lower load. Your POLARIS dealer can assist...

  • Page 110: Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
  • Page 111 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. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 112 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 113 Kohler Co. provides the California and Federal emission control warranty on this vehicle. However, you may always utilize your Polaris dealer as a first point of contact for standard warranty or emissions warranty requests. While most inquiries can be resolved by working with your Polaris dealer, any unresolved emission-related concerns can be pursued further with Kohler Co.
  • Page 114 WARRANTY COVERAGE Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts. The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co.

  • Page 115: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 116 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 117: Index

    INDEX Accessory Outlets ......22 Differential Lock Switch ....23 Air Filter .
  • Page 118 Plugs, Spark ......74 Polaris Products ......104 Polishing the Vehicle.
  • Page 119 INDEX Shifter ........22 Under-Seat Storage ......25 Shifting Gears .
  • Page 121 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9928298 Rev 01 Printed in USA...

This manual is also suitable for:

Ranger crew 1000 dieselRanger 1000 diesel eps

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