Polaris Ranger 400 HO Owner's Manual
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Polaris Ranger 400 HO Owner's Manual

Polaris ranger 400 ho utv owner's manual
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  • Page 2 Pantone 426C 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 . On public roads. A collision can occur with another vehicle. With more than ONE passenger, or with a passenger under age twelve or who cannot comfortably reach the floor and hand holds.
  • 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 No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 RANGER 400 HO Owner’s Manual P/N 9922123...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction ......4 Safety ....... . . 7 Features and Controls .

  • Page 8: 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 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.

  • 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

    SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

  • Page 12: Clutch Cover Warning

    SAFETY Safety Labels and Locations Age 16 Warning Discretionary Warning Age 16 Operating this vehicle if you are under the age of 16 increases your Warning Shift Caution chance of severe injury or death. NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver’s license.

  • Page 13: Discretionary Warning

    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°.

  • 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. •...

  • 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 34. 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 ROPS Cab Frame Hip Bar Console Cargo Box Fuel Tank Cap Headlights Radiator Front Bumper/Brush Guard...

  • Page 23: Component Locations

    FEATURES AND CONTROLS Component Locations Tailgate Latch Releases Tailgate Muffler (Spark Arrestor) Receiver Hitch CV Boot/Rear Caliper 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 40-43.

  • Page 24: Indicator Lights

    FEATURES AND CONTROLS Console Indicator Gear Selector Storage Lights (Shifter) Compartment Storage 12V Auxiliary Holder Tray Outlets 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 FEATURES AND CONTROLS Switches Ignition Switch/Light Switch The ignition switch is a four-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.

  • Page 26: Gear Selector

    FEATURES AND CONTROLS Gear Selector H: High Gear Gear Selector L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driv- ing range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads.

  • Page 27: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Throttle Pedal Brake Push the pedal down to increase Pedal engine speed. Spring pressure returns the pedal to the rest posi- tion when released.
  • Page 28 FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all rid- Latch Plate ers before operating. The center of the seat is NOT equipped with a seat belt.

  • Page 29: 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 30: Seat Removal

    FEATURES AND CONTROLS Roll-Over Protection System (ROPS) The Rollover Protective Structure (ROPS) on this ROPS Cab vehicle meets OSHA 1928.53 Frame rollover performance require- ments. Always have your authorized Polaris dealer thor- oughly inspect the ROPS if it ever becomes damaged in any way.

  • Page 31: 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 32 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 55. Add the recommended oil as needed to maintain the oil level between the safe and add marks. 3.
  • Page 33 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 34: Starting The Engine

    OPERATION Starting the Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Turn the fuel valve on. 3. Sit in the driver's seat and fasten the seat belt. 4. Apply the brakes. Place the transmission in PARK. 5.

  • Page 35: Stopping The Engine

    OPERATION Starting the Engine 9. If a warm engine has cooled to a point where it does not readily start, intermittent use of the choke (half way out) may be necessary. If the engine is over-choked when warm, depress the throttle pedal fully while cranking to aid in starting.

  • Page 36: 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 37: 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 38: Driving Uphill

    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.

  • Page 39: 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 40: 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 41: 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 42: Driving In Reverse

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

  • Page 43: 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 PARK. 3. Turn the engine off. 4. Block the rear wheels on the downhill side.

  • Page 44: 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 45 Never exceed the following capacities. Model Maximum Capacities Cargo Box (Level Ground) RANGER 400 HO 1000 lbs. (454 kg) 500 lbs. (227 kg) WARNING! Driving with passengers in the cargo box can result in severe injury or death.

  • Page 46: 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. Place the transmission in PARK. 4. Dismount the vehicle. 5.

  • Page 47: 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 tow- ing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket. 2.

  • Page 48: 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 49: Disengaging Awd

    OPERATION All Wheel Drive (AWD) Press the top of the rocker switch to engage 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.

  • Page 50: 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. Locking the differential in slippery or low traction conditions helps improve traction.

  • Page 51: 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 52: 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 53: Periodic Maintenance Chart

    MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) 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 54 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 29. Rear suspension Pre-Ride Tires...
  • Page 55 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 General 50 H Lubricate all fittings, pivots,...
  • Page 56 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, filter, pump, carburetor; replace lines every two years Fuel filter 100 H 12 M Replace yearly...

  • Page 57: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 48, 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 58: Engine Oil

    MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. 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 59: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. See page 54 for oil recom- mendations. Oil Check The oil tank is located under the seat. 1. Position the vehicle on a level surface.

  • Page 60: 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 48. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface.
  • Page 61 MAINTENANCE Engine Oil Oil and Filter Change 12. Place shop towels under the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing sur- face on the engine. 14.
  • Page 62 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 63: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 43.6 oz. 14 ft. lbs. 14 ft. lbs. (Transmission) Synthetic (1290 ml) (19.4 Nm) (19.4 Nm) Gearcase Lube Front Gearcase Premium Demand 9.3 oz.
  • Page 64 MAINTENANCE Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants, capacities and torque specifications.
  • Page 65 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants, capacities and torque specifications.

  • Page 66: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 98 for the recom- mended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
  • Page 67 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.

  • Page 68: 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 69: Adding Or Changing Coolant

    MAINTENANCE Cooling System Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 70 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

  • Page 71: 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 48. 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 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.

  • Page 73: 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 74: 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 75: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Service the air filter more fre- quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.
  • Page 76 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-...
  • Page 77 MAINTENANCE Carburetor The idle speed adjustment should be performed as outlined in the Peri- odic Maintenance Chart, or whenever the idle speed is changed. Recom- mended engine idle RPM is 1200 +/- 200. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is unsatisfactory and all other conditions are favorable, the carburetor can be adjusted.

  • 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 plug located on the bottom of the muf- fler. 2. Place the transmission in Clean-Out PARK. Plug 3. Start the engine. 4.

  • 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 Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster. 3. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. Boot 4.

  • 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 23. 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: Suspension Adjustments

    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.

  • Page 85: 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 86: Wheel Removal

    MAINTENANCE Tires Wheel Removal 1. Apply the brakes. 2. Place the transmission in PARK. 3. Stop the engine. 4. Loosen the wheel nuts slightly. 5. Elevate the side of the vehicle by placing a suitable stand under the frame. 6. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1.

  • Page 87: 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 88: 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 89: 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 90 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 91: 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 92: Battery Installation

    MAINTENANCE Battery Battery Installation NOTICE: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Always install a fully charged battery. 1. Ensure that the battery is fully charged.

  • Page 93: 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 94 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 87. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 95 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 96: 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 97: Washing 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 98 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.

  • Page 99: Storage Tips

    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 92.
  • Page 100 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 48. • 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 101: 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 102: Specifications

    SPECIFICATIONS RANGER 400 HO Maximum Weight Capacity 1000 lbs. (454 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1050 lbs. (476 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.25 qts. (2.4 l) Overall Length 108 in.
  • Page 103 SPECIFICATIONS RANGER 400 HO Driving System Type Shift Type Single Lever (console) Gear Reduction - Low 7.70:1 Gear Reduction - Reverse 7.00:1 Gear Reduction - High 4.12:1 Drive Ratio - Front 3.818:1 Tire Size - Front 25 x 8 - 12...

  • Page 104: 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 105: 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 34. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently.
  • Page 106 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 connections Inspect, clean, reinstall connectors Engine Turns Over, Fails to Start Possible Cause Solution...
  • Page 107 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 108 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect, clean and/or replace spark plug 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...

  • Page 109: 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...

  • Page 110: 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 (if equipped) for failure due to defects.
  • Page 111 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 112 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 113 You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age. You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country.
  • Page 114 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 115 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.

  • Page 116: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 117 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 118 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

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2010 ranger 400 ho

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