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Table of Contents
Related Manuals for Polaris Ranger 4X4
Summary of Contents for Polaris Ranger 4X4
- Page 3 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
- Page 4 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
- Page 5 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ® •...
- Page 6 POLARIS, POLARIS THE WAY OUT and RANGER are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
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Page 7: Table Of Contents
TABLE OF CONTENTS Vehicle Identification Numbers... . . 4 Safety ....... . . 7 Features and Controls . - Page 8 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 sym- bols are used.
- Page 9 INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. 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.
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Page 10: Vehicle Identification Numbers
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. 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. -
Page 11: Safety
RANGER - 6X6 FRONT 10 (69) CENTER 10 (69) REAR 10 (69) MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO, AND ACCESSORIES. RANGER 4X4 is 1500 LBS. (682 KG) RANGER 6X6 is 2000 LBS. (907 KG) Reduce speed and allow greater distance for braking when carrying cargo. -
Page 12: Clutch Cover Warning
SAFETY Safety Labels and Locations Shift Caution Discretionary Warning Age 16 Clutch Cover Warning Warning Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death. - Page 13 SAFETY Safety Labels and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees 15°.
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Page 14: 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 manual and all labels carefully. Follow the operating procedures described. - Page 15 SAFETY Operator Safety • Always inspect your vehicle each time you use it to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. • Always travel slowly and use extra caution when operating on unfamiliar terrain.
- Page 16 SAFETY Operator Safety • Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stop- ping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads. •...
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Page 17: Equipment Modifications
SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these pur- poses. -
Page 18: Age Restrictions
SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn, 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. -
Page 19: Handling Gasoline
SAFETY Operator Safety Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect your RANGER before each use to make sure it's in safe operating condition. -
Page 20: Operating On Pavement
SAFETY Operator Safety Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn. -
Page 21: Improper Hill Climbing
SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 36. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill. -
Page 22: Features And Controls
FEATURES AND CONTROLS Component Locations Not all models come with all features. Refer to the specifications section beginning on page 100. Hip Bar Console Cargo Box Fuel Tank Cap ROPS Cab Frame Headlights Radiator Front Bumper/Brush Guard... -
Page 23: Component Locations
FEATURES AND CONTROLS Component Locations Tailgate Tailgate Latch Release Receiver Hitch CV Boot/Rear Caliper Muffler (Spark Arrestor) Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 42-45. -
Page 24: Auxiliary Outlets
FEATURES AND CONTROLS Console Fuel Gauge Park Brake Lever Gear Selector Indicator Lights (Shifter) Storage 12V Auxiliary Compartment Storage Holder Outlets Tray Auxiliary Outlets The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood. -
Page 25: Indicator Lights
FEATURES AND CONTROLS Indicator Lights The indicator light panel is located on the console. Low Gear Reverse (if equipped) Gear Park Brake High High Neutral Temperature Gear Gear Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse Low gear is the primary driving range for the RANGER. -
Page 26: Ignition Switch
FEATURES AND CONTROLS Switches Light Switch AWD/Differential Switch 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 27: Light Switch
FEATURES AND CONTROLS Switches Light Switch The ignition switch key must be in the ON/ RUN position to operate the headlights. Use the light switch to turn the headlights on or off. AWD/Differential Lock Switch The AWD/Differential Switch has three posi- tions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/ Turf Mode). -
Page 28: Brake Pedal
FEATURES AND CONTROLS Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider pref- erence. Lift and hold the adjustment lever toward you while tilting the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. -
Page 29: Park Brake Lever
FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, except neutral. - Page 30 FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three-point lap and diagonal seat belts on all external seats.The center seat is equipped with a lap-style seat belt. Always Latch Plate make sure the seat belts are secured for all riders before operating.
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Page 31: Seat Belt Inspection
FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. - Page 32 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your autho- rized 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.
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Page 33: Operation
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, 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 34 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 2. Check the oil level. See page 57. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.
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Page 35: Pre-Ride Inspection
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi- tion 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... -
Page 36: Starting Engine
OPERATION Starting Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. 3. Apply the brakes. Engage the park brake. 4. Shift the transmission to neutral. 5. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START. -
Page 37: Stopping The Engine
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Apply the brakes. 4. Engage the park brake. WARNING! A rolling vehicle can cause serious injury. Always engage the park brake after stopping the engine. -
Page 38: Driving Procedure
OPERATION Driving Procedure 1. Wear a helmet and eye protection. 2. Sit in the driver's seat and fasten the seat belt. 3. Start the engine and allow it to warm up. 4. Apply the service brakes and shift the transmission into gear. 5. -
Page 39: Driving On Slippery Surfaces
OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (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 40 OPERATION Driving Uphill Whenever traveling uphill, follow these pre- cautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 15° maximum 4. Always check the terrain carefully before ascending any hill. 5.
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Page 41: Driving Downhill
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. -
Page 42: Driving Through Water
OPERATION Driving Through Water Your Polaris RANGER can operate through water up to a maximum rec- ommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. -
Page 43: Driving Over Obstacles
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. -
Page 44: 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 45: Parking On An Incline
OPERATION Parking on an Incline 15° maximum Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in gear. 3. Engage the park brake. 4. Turn the engine off. 5. -
Page 46: 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 47 Never exceed the following capacities. Model Maximum Capacities Cargo Box (Level Ground) RANGER 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg) WARNING! Driving with passengers in the cargo box can result in severe injury or death.
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Page 48: Dumping The Cargo Box
OPERATION 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. Apply the brakes. 3. Engage the park brake. 4. Dismount the vehicle. 5. -
Page 49: Towing Loads
Total Hitch Maximum Load Weight Load Weight Vertical Towing (Level Ground) (15° grade) Weight Speed RANGER 4X4 1500 lbs. 850 lbs. 150 lbs. 10 mph (681 kg) (386 kg) (68.1 kg) (16 kph) Belt Life To extend belt life, use the lowest gear possible when hauling or towing... -
Page 50: 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 51 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differen- tial. Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed.
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Page 52: Disengaging Awd
OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. -
Page 53: 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 Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c. -
Page 54: Maintenance
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. - Page 55 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. WARNING! Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.
- Page 56 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering Pre-Ride Make adjustments as need ed. See Pre-Ride Checklist Front suspension Pre-Ride on page 31. Rear suspension Pre-Ride Tires...
- Page 57 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine breather 25 H Monthly Inspect; replace if necessary filter (if equipped) Engine oil change 25 H Perform a break-in oil change (break-in) at one month Park brake cable 25 H Check tension, adjust...
- Page 58 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Fuel system 100 H 12 M Check for leaks at tank cap, lines, fuel valve, pump, throt- tle body; replace lines every 2 years Radiator 100 H 12 M Inspect;...
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Page 59: Lubrication Recommendations
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 50, 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 60: Engine Oil
MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. -
Page 61: Oil Check
MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. See page 56 for oil recom- mendations. Oil Check The oil tank is located under the seat. 1. Position the vehicle on a level surface. -
Page 62: 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 50. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. - Page 63 MAINTENANCE Engine Oil Oil and Filter Change 10. Reattach the oil line. 11. Place shop towels beneath the oil filter. Using an oil fil- ter wrench, turn the filter counterclockwise to remove 12. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase.
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Page 64: Oil Pump Priming
MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2"... - Page 65 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level even with the bottom of the fill plug hole threads. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications.
- Page 66 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 60 for recommended lubricants, capacities and torque specifications.
- Page 67 MAINTENANCE Gearcases Front Gearcase Oil Change 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's side. 3. Remove the fill plug. 4. Place a drain pan under the drain plug on the bottom right-hand side.
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Page 68: Spark Plugs
Spark Plug Gap/Torque Model Electrode Gap New Plug Used Plug Torque Torque RANGER 4X4 .036" (.9 mm) 9-11 ft. lbs. 9-11 ft. lbs. (12-15 Nm) (12-15 Nm) Spark Plug Inspection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. - Page 69 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be white.
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Page 70: Cooling System
MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. -
Page 71: Radiator And Cooling Fan
MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 50. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan. -
Page 72: Radiator Coolant Level
MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 50. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan. - Page 73 MAINTENANCE Polaris Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced.
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Page 74: Pvt System
MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys- tem. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug. -
Page 75: Vehicle Immersion
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below. -
Page 76: Filter Systems
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Service the air filter more fre- quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. - Page 77 MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line out the side of the air box and locate the filter. 3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clog-...
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Page 78: Spark Arrestor
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. - Page 79 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs located on the bottom of the muffler. 2. Shift the transmission to neutral. Apply the brakes. Start the engine.
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Page 80: Throttle System
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasionally during operation. -
Page 81: Throttle Freeplay Adjustment
MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster. -
Page 82: Brake Fluid
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 24. 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 83: Brake Inspection
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear. -
Page 84: Steering Wheel Inspection
MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause illumination of the park brake light and activation of the limiting feature. - Page 85 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus- pension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting holes. 2. Reposition the shocks to the outside mounting holes. 3.
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Page 86: Tire Tread Depth
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. -
Page 87: Wheel Removal
MAINTENANCE Tires Wheel Removal 1. Apply the brakes. Engage the park brake. 2. Stop the engine. Place the transmission in gear. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. -
Page 88: 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. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. -
Page 89: 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 approxi- mately 25 ft. (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 90: Indicator Lamp Replacement
MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel. - Page 91 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.
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Page 92: Battery Removal
MAINTENANCE Battery Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1. -
Page 93: Battery Installation
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 91 before installing the battery. -
Page 94: Battery Storage
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. - Page 95 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 88. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
- Page 96 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
- Page 97 MAINTENANCE Fuses Fuse Feature Supported Accessories, 12V Power Receptacle Electronic Fuel Injection Lights Main Fuse - Ignition 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.
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Page 98: Cleaning And Storage
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. -
Page 99: Polishing The Vehicle
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the follow- ing items: •... - Page 100 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
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Page 101: Battery Maintenance
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 94. -
Page 102: Fluid Levels
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 50. • Front and rear gearcase fluid (if equipped) • Transmission fluid • Brake fluid (change every two years and any time the fluid looks dark or contaminated) •... -
Page 103: Removal From Storage
MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. -
Page 104: Specifications
SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity 1500 lbs. (681 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1214 lbs. (551 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.25 qts. (3 l) Overall Length 114 in. - Page 105 SPECIFICATIONS RANGER 4X4 Lubrication System Dry Sump Engine Oil 0W/40 Driving System Type Shift Type Single Lever (console) Gear Reduction - Low 7.7:1 Gear Reduction - Reverse 7.0:1 Gear Reduction - High 4.12:1 Drive Ratio - Front: 3.818:1 Drive Ratio - Rear 3.105:1...
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Page 106: Polaris Products
POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) 2871653... -
Page 107: Troubleshooting
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 36. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently. - Page 108 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or Disconnect the connector if temporary switch movement or failure continued operation is necessary, see your dealer promptly for service Engine Doesn't Turn Over Possible Cause...
- Page 109 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
- Page 110 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range...
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Page 111: Declaration Of Conformity
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS 98/37/EC as amended (Machinery Directive) EN 1050 hazard analysis... -
Page 112: Warranty
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. - Page 113 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: •...
- Page 114 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
- Page 115 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.
- Page 116 WARRANTY 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 applica- ble U.S.
- Page 117 WARRANTY U.S.A. EPA Emissions Limited Warranty 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 prod- ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.
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Page 118: Maintenance Log
MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS... - Page 119 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
- Page 120 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
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Page 121: Index
INDEX Accessory Outlets ....20 Cab Frame, ROPS....28 Adjustment Cargo..... . 42-43 Park Brake. - Page 122 INDEX Emissions Limited Warranty . . 112-113 Freeplay Adjustment, Throttle..77 Engaging AWD ....48 Freeplay, Throttle ....76 Engine Break-In.
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Page 123: Index
INDEX Lamp Replacement, Indicator Lights 86 Park Brake ....25 Light Switch ....23 Park Brake Adjustment. - Page 124 INDEX Spark Plug Recommendations..64 Towing Loads ....45 Spark Plug Torque ....64 Towing Speed .