Page 1 RANGER® 1000 RANGER® 1000 CREW Owner's Manual For Maintenance and Safety...
Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
Page 3 2020 Owner’s Manual RANGER® 1000 RANGER CREW® 1000...
Page 4 POLARIS®, RANGER®, and POLARIS GENERAL™ are trademarks of POLARIS Industries Inc. Copyright 2019 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 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 6 SAFETY SYMBOLS AND SIGNAL WORDS 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
Page 7 Specifications ....145 POLARIS Products ....151 Troubleshooting ....153 Warranty .
Page 9 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
Page 10 INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 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 11 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 13 SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course.
Page 14 SAFETY RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area. The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time.
Page 15 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. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
Page 16 SAFETY PAYLOAD WARNING/SHIFT CAUTION RANGER NEVER EXCEED IF TOTAL PAYLOAD EXCEEDS 40 mph (64 kph) 550 lbs. (250 kg) 1000 25 mph (40 kph) 1050 lbs. (476 kg) 40 mph (64 kph) 550 lbs. (250 kg) CA 1000 25 mph (40 kph) 1050 lbs.
Page 17 If an informational or graphic 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. The safety labels are located on the front ROPS, above the driver’s head.
Page 18 SAFETY SEAT BELT / DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use vehicle cab doors if equipped. •...
Page 19 AIR BOX CAUTION CAUTION Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube. The air filter must be properly seated before the lid is reinstalled.
Page 20 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.
Page 21 If an informational or graphic 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. The safety labels are located on the front ROPS, above the driver’s head.
Page 22 SAFETY SEAT BELT / DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use vehicle cab doors if equipped. •...
Page 23 SAFETY LOAD/PASSENGER/TIRE PRESSURE WARNING The Load/Passenger/Tire Pressure Warning is located in the cargo box. WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. • If total payload is greater than 500 lbs, the vehicle must be operated in LOW range.
Page 24 AIR BOX CAUTION CAUTION Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube. The air filter must be properly seated before the lid is reinstalled.
Page 25 SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle 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 and in the safety DVD provided with your vehicle.
Page 26 • 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 27 SAFETY • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. •...
Page 28 SAFETY USING ALCOHOL OR DRUGS WARNING Never consume alcohol or drugs before or while operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
Page 29 SAFETY CAB DOORS Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests.
Page 30 SAFETY OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.
Page 31 SAFETY OPERATING ON PUBLIC ROADS WARNING Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off- highway use).
Page 32 SAFETY DESCENDING HILLS IMPROPERLY CAUTION Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual. CROSSING HILLSIDES CAUTION Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover.
Page 33 SAFETY OPERATING IN UNFAMILIAR TERRAIN CAUTION Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover. CAUTION Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover. Travel slowly and use extra caution when operating on unfamiliar terrain.
Page 34 SAFETY OPERATING OVER OBSTACLES CAUTION Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.
Page 35 SAFETY IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. • Never exceed the stated load capacity for this vehicle. •...
Page 36 EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
Page 37 FEATURES AND CONTROLS FEATURES AND CONTROLS RANGER 1000 COMPONENT LOCATIONS Console Receiver Hitch Headlights ROPS Cab Frame Radiator Hip Bar Bumper Cargo Box Tailgate Fuel Cap Taillights Fuse Block (underneath seat) CV Boot/Rear Caliper...
Page 38 FEATURES AND CONTROLS RANGER CREW 1000 COMPONENT LOCATIONS Console Receiver Hitch Headlights ROPS Cab Frame Radiator Hip Bar Bumper/Brush Guard Fuel Cap Tailgate Cargo Box Taillights Fuse Block (under seat) CV Boot/Rear Caliper...
Page 39 FEATURES AND CONTROLS CONSOLE Steering Wheel Adjustment Lever Light Switch Instrument Cluster AWD Switch Ignition 12V Auxiliary Outlets Gear Selector (Shifter) Storage Compartment STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward.
Page 40 PARK. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.
Page 41 FEATURES AND CONTROLS USING LOW GEAR Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK. Always shift into low gear for any of the following conditions.
Page 42 FEATURES AND CONTROLS SWITCHES Not all switches are present on every model. 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. Electrical circuits are on.
Page 43 FEATURES AND CONTROLS AWD SWITCH The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode). Press the top of the switch to engage All Wheel Drive (AWD). Move the switch to the center position to lock the differential and operate in two wheel drive (2WD).
Page 44 FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1.
Page 45 FEATURES AND CONTROLS PARK BRAKE LEVER (IF EQUIPPED) Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited.
Page 46 FEATURES AND CONTROLS SEATING - STANDARD MODELS SEAT REMOVAL Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
Page 47 FEATURES AND CONTROLS 1. For 3-point belts, pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.
Page 48 FEATURES AND CONTROLS SEATING - LE MODELS SEAT REMOVAL To remove the driver’s seat, lift up on the rear of the seat and rotate the seat base up and forward. To put the passenger seat into the upright position, lift up on the front of the seat and raise it to the upright position.
Page 49 FEATURES AND CONTROLS 3. Release the strap, it will self tighten. 4. To release the seat belt, press the square red button in the buckle’s center. SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle. 1.
Page 50 EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
Page 51 FEATURES AND CONTROLS OPENING THE NET 1. To exit the vehicle, release the top front latch. 2. Rotate the net rearward and slide the lower net rod out of the mount to remove it. 3. Allow the net to hang freely outside the vehicle while dismounting. ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements.
Page 52 Fuel Gauge segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled Service Indicator maintenance. See page 60 for more information.
Page 53 This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine Check Engine damage could result. Your authorized POLARIS dealer can assist. This indicator illuminates when a fault has occurred in the EPS Warning (if EPS system.
Page 54 FEATURES AND CONTROLS DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Engine Speed Temperature Ambient Temperature (Optional)
Page 55 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 Engine Odometer Temperature Ambient Temperature Trip 1 (Optional) Trip 2 Voltage Speed Engine Hours Service Hours...
Page 56 FEATURES AND CONTROLS OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH Units - Temp Select between °F and °C Clock Select between 12H or 24H, and set...
Page 57 FEATURES AND CONTROLS UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units-Distance” from the Options Menu by pressing the MODE button.
Page 58 FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 59 FEATURES AND CONTROLS CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 60 FEATURES AND CONTROLS 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. BACK LIGHT COLOR 1.
Page 61 FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.
Page 62 FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 63 FEATURES AND CONTROLS DIAGNOSTIC CODE NOTICE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
Page 64 FEATURES AND CONTROLS DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart.
Page 65 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Injector 1 (MAG) (SDI Driver Circuit Open/ Part Load) Grounded Driver Circuit Short to Driver Circuit Grounded Injector 2 (PTO) (SDI Driver Circuit Open/ Part Load) Grounded Driver Circuit Short to Driver Circuit Grounded Ignition Coil Primary Driver Circuit Short to...
Page 66 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Driver Circuit Short to 1321 Driver Circuit 1321 Grounded Chassis Relay Driver Circuit Open/ 520208 Grounded Driver Circuit Short to 520208 Driver Circuit 520208 Grounded All Wheel Drive Driver Circuit Open/ 520207 Control Grounded Driver Circuit Short to 520207...
Page 67 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Abnormal Rate Of Change Received Network Data In Error System Power Data Valid But Above Normal Operational Range - Most Severe...
Page 68 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Steering Torque Condition Exists 520223 Partial Failure Steering Torque Full Condition Exists 520224 Failure EPAS Inverter Data Valid But Above Temperature Normal Operational 520225 Range - Most Severe Level Data Valid But Above Normal Operating 520225 Range - Moderately...
Page 69 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 safety warnings outlined in the safety section of this owner’s manual.
Page 70 3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 4. Never operate with accessories not approved by POLARIS for use on this vehicle. 5. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).
Page 71 OPERATION 6. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly. 7. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience.
Page 72 Ensure proper operation page 51 page 40 Intake pre-filters Inspect, clean Headlamps Check operation, apply POLARIS dielectric page 130 grease when lamp is replaced Brake light/tail lamps Check operation Seat Latch Push down on the seat back to ensure the latch...
Page 73 OPERATION ITEM REMARKS PAGE Cab Doors (if equipped) Check doors and latches for wear or damage. Grass and leaves Remove grass, leaves, and other flammable material or debris, especially near the exhaust system.
Page 74 OPERATION STARTING THE ENGINE 1. Position the vehicle on a level surface outdoors or in a well ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab doors (if equipped). 3. Place the transmission in PARK. 4.
Page 75 OPERATION BRAKING 1. Release the throttle pedal completely. CAUTION When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking. 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.
Page 76 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
Page 77 OPERATION WARNING If the vehicle is capable, never exceed: 40 mph (64 kph) if total payload exceeds 550 lbs. (250 kg) or 25 mph (40 kph) if total RANGER 1000 payload exceeds 1050 lbs. (476 kg). 40 mph (64 kph) if total payload exceeds 550 lbs.
Page 78 OPERATION 4. Do not tow more than the recommended weight for the vehicle. 5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle. 6.
Page 79 OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 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. Apply the brakes. 3.
Page 80 OPERATION ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential. ENGAGING AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage.
Page 81 OPERATION DISENGAGING AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction. In some situations, the front gearcase may remain locked after turning the AWD switch off.
Page 82 OPERATION UNLOCKING THE DIFFERENTIAL (TURF MODE) When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings.
Page 83 OPERATION 5. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 6. The driver must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. 7. Sit in the driver's seat and fasten the seat belt. 8.
Page 84 OPERATION 3. Make sure all passengers are wearing helmet, eye protection, gloves, long- sleeve shirt, long pants and over-the-ankle boots. 4. Make sure all cab doors (if equipped) are properly secured. 5. Do not carry more than the recommended number of passengers for your vehicle.
Page 85 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.
Page 86 OPERATION 5. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly. 6. Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover. DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1.
Page 87 OPERATION 3. Avoid crossing the side of a steep hill. 4. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards.
Page 88 OPERATION 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2.
Page 89 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 90 WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
Page 91 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. 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 92 WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
Page 93 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, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle.
Page 94 WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
Page 95 WINCH GUIDE 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 96 Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
Page 97 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 98 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, or other qualified person.
Page 99 EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.
Page 101 PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
Page 102 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized 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.
Page 103 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES HOURS CLNDR (KM) Engine Breather Inspect; replace as needed 50 H (800) Shift Linkage Inspect, lubricate, adjust 50 H (800) Steering 50 H Lubricate (800) Front / Rear Lubricate and inspect bushings 50 H (800) Stabilizer Bars...
Page 104 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES HOURS CLNDR (KM) 1000 Spark Plug Inspect; replace as needed 100 H 12 M (1600) Inspect for wear, routing, security; 1000 Wiring inspect connectors subjected to 100 H 12 M (1600) water, mud, etc.
Page 105 MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
Page 106 POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
Page 107 MAINTENANCE 3. Raise the cargo box. Unlock the dipstick lever . Remove the dipstick and wipe it dry with a clean cloth. 4. Reinstall the dipstick and push it into place. Do not lock the dipstick. NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.
Page 108 MAINTENANCE ENGINE OIL AND FILTER REPLACEMENT Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover.
Page 109 MAINTENANCE 8. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification. TORQUE Oil Filter: Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn.
Page 110 MAINTENANCE 20. When finished, reinstall the oil fill cap, oil dipstick and lock the lever. 21. Dispose of used oil and filter properly. GEARCASES GEARCASE SPECIFICATION CHART DRAIN PLUG/ FILL PLUG LEVEL GEARCASE LUBRICANT CAPACITY TORQUE CHECK PLUG TORQUE AGL Gearcase Transmission 41 oz.
Page 111 MAINTENANCE TRANSMISSION OIL CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate. 1. Remove the fill plug 2. Place a drain pan under the drain plug 3.
Page 112 MAINTENANCE DEMAND DRIVE OIL CHANGE 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the passenger's side. 3. Remove the fill plug. 4. Place a drain pan under the drain plug on the bottom right-hand side. 5.
Page 113 Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP/TORQUE ELECTRODE GAP NEW OR USED PLUG TORQUE 0.85 mm Nominal...
Page 114 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. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
Page 115 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 116 MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface.
Page 117 • See your dealer or other qualified service person 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 118 MAINTENANCE BELT REMOVAL If a belt fails, always clean any debris from the clutch air 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 119 MAINTENANCE 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 4. Insert clutch spreader tool into threaded hole on driven clutch as shown and turn clockwise to spread clutch. NOTE Clutch spreader tool part number 2875911 is found in vehicle tool kit. 5.
Page 120 MAINTENANCE BELT INSTALLATION NOTE Be sure to install belt in the same direction as it was removed. 1. With the clutch spreader tool installed, loop the belt over the drive clutch and over the driven clutch. 2. Rotate the driven clutch and walk the belt into the clutch. 3.
Page 121 TORQUE PVT Outer Cover Fasteners 44 in-lbs. (5 N⋅m) POLARIS VARIABLE TRANSMISSION (PVT) DRYING There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Position the vehicle on a level surface.
Page 122 6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist. VEHICLE IMMERSION...
Page 123 MAINTENANCE FILTER SYSTEMS AIR FILTER REPLACEMENT Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often. 1. Tilt the rear cargo box to access the airbox. 2.
Page 124 MAINTENANCE 4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel. NOTE If the filter has been soaked with fuel or oil it must be replaced. DO NOT attempt to clean the air filter. 5.
Page 125 MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
Page 126 MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. 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 127 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.
Page 128 MAINTENANCE FRONT SUSPENSION ADJUSTMENT The front suspension 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).
Page 129 MAINTENANCE REAR CAM ADJUSTMENTS The rear suspension cams can be adjusted to provide a stiffer suspension, if necessary. Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension. Always heed the following rules if you make adjustments to this suspension.
Page 130 Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
Page 131 MAINTENANCE WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5.
Page 132 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. Always make sure lights are adjusted properly for best visibility.
Page 133 MAINTENANCE HEADLIGHT ADJUSTMENT The headlight beams are adjustable. 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. ITEM DESCRIPTION Measure Distance = 7.5 in (19.0 cm) Measure Distance = 25 ft (7.6 m) Headlight Center of Bulb 2.
Page 134 MAINTENANCE 5. Adjust the beam to the desired position by loosening or tightening the bottom screw and moving the lamp to the appropriate height. 6. Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. WARNING Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty.
Page 135 MAINTENANCE FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse box is located under the hood.
Page 136 MAINTENANCE BATTERY WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
Page 137 MAINTENANCE If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 1510 1.5 AMP (PN 2830404) or 12V 1.5 AMP Convertible BatteryMINDer® (PN 2830511), which can be ordered through your dealer. During charging, place the charger outside of the vehicle and protect it from moisture.
Page 138 Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge.
Page 139 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 140 Replacement safety labels are provided by POLARIS at no charge. 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 141 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
Page 142 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
Page 143 MAINTENANCE REMOVAL FROM STORAGE WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle.
Page 144 MAINTENANCE TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle. 1. Apply the brakes. 2. Place the transmission in PARK. Stop the engine. 3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 4.
Page 145 MAINTENANCE FRONT TIE-DOWN LOCATION Front tie-down points, one or both...
Page 146 MAINTENANCE REAR TIE-DOWN LOCATION Rear tie-down points...
Page 147 SPECIFICATIONS SPECIFICATIONS RANGER 1000 Maximum Weight 1500 lbs. (680 kg) (including operator, passengers, Capacity (includes cargo, accessories) weight of operator, 1100 lbs. (499 kg) (Models sold in California) passenger, cargo, accessories) Dry Weight 1,527 lb (692.6 kg) Test GVW - 3600 lbs.
Page 148 SPECIFICATIONS Alternator Output 660 W @ 3000 RPM or 900 W @ 3000 RPM (if equipped) Compression Ratio 10.5:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32° +/- 2° @ 5000 RPM Spark Plug/ Gap Autolite 5684 / 0.85 mm Nominal Lubrication System Wet Sump...
Page 149 SPECIFICATIONS Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlights 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W)
Page 150 SPECIFICATIONS RANGER CREW 1000 Maximum Weight 1750 lbs. (794 kg) (including operator, passengers, Capacity (includes cargo, accessories) weight of operator, 1350 lbs. (612 kg) (Models sold in California) passenger, cargo, accessories) Dry Weight 1786 lbs. (810.1 kg) Test GVW - 3750 lbs.
Page 151 SPECIFICATIONS Compression Ratio 10.5:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32° +/- 2° @ 5000 RPM Spark Plug/ Gap Autolite 5684 / 0.85 mm Nominal Lubrication System Wet Sump Cooling Liquid Front Suspension Dual A-Arm, IFS 10.0” (25.4 cm) Travel Rear Suspension Dual A-Arm, IRS 10.0"...
Page 152 SPECIFICATIONS Hood Headlights 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W)
Page 153 Dielectric Grease (Nyogel™) — 2871329 12 oz bottle (12) Carbon Clean 2871326 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 DOT 4 Brake Fluid — 2872189 Loctite™ 565 Thread Sealant — 2871956 POLARIS Battery Tender™ — 2859044 Charger...
Page 155 TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground Drive at a higher speed or use low range more frequently. speed (3-7 MPH) Warm the engine at least 5 minutes.
Page 156 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE...
Page 157 TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug...
Page 158 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires...
Page 159 This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
Page 160 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
Page 161 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 162 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 163 IS SOLD OUTSIDE THE COUNTRY OF THE 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.
Page 164 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
Page 165 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
Page 166 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
Page 167 As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Page 169 MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
Page 171 Cold Weather Operation....72 Component Locations..... 35-36 Adding or Changing Coolant ..112 Cooling System......112 Age Restrictions ......25 Crankcase Emission Control AGM Battery Maintenance and System ........97 Charging ......134 Crossing Hillsides ...... 30 Air Box Caution ....17, 22 Air Filter / Air Box.....
Page 172 Exported Products ....161 Instrument Cluster Exposure to Exhaust ....33 Back Light Color ..... 58 Eye Protection ......13 Back Light Level ..... 59 Clock ........57 Diagnostic Code..... 61 Display Area 1 ....... 52 Display Area 2 ....... 53 Failure to Inspect Before Indicator Lamps .....
Page 173 Spark Arrester ......123 Periodic Maintenance Chart ..99 Spark Plug Gap/Torque....111 Plugs, Spark......111 Spark Plug Inspection....111 Polaris Products ...... 151 Spark Plug Recommendations ..111 POLARIS Variable Specifications ....145, 148 Transmission (PVT) Drying ..119 Stabilize the Fuel ..... 139 POLARIS Variable Stalling While Climbing a Hill ..
Page 174 Trailer Hitch Bracket....49 Transmission Oil Change ..109 Transmission Oil Check .... 108 Transporting the Vehicle.... 142 Turning Improperly..... 29 Unauthorized Use of the Vehicle ... 34 Vehicle Identification Numbers ..9 Vehicle Immersion ....120 Warning Symbols ......4 Warranty Coverage And Exclusions Lubricants and Fluids ....
Page 176 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. 9930790 Rev 01 Printed in USA...

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