Polaris 2013 RANGER 500 Midsize Owners Manual/Install Manual
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Polaris 2013 RANGER 500 Midsize Owners Manual/Install Manual

Polaris 2013 RANGER 500 Midsize Owners Manual/Install Manual

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RANGER® 500
Midsize
RANGER CREW® 500
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 2013 RANGER 500 Midsize

  • Page 1 RANGER® 500 Midsize RANGER CREW® 500 Owner's Manual for Maintenance and Safety...
  • Page 2 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 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 On paved surfaces - pavement may seriously affect handling and control. With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: Wear your seat belt. Vehicle rollover could cause severe injury or death.
  • Page 5 Master Service Dealer® (MSD) technician. Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty...
  • Page 6 POLARIS, RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc. Copyright 2012 POLARIS Sales 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 produc- tion components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 7: Table Of Contents

    Specifications ........74 POLARIS Products........76 Troubleshooting .

  • Page 8: Introduction

    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 9: Vehicle Identification Numbers

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

  • Page 10: Safety

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 11 • On paved surfaces - pavement may seriously affect handling and control. • With non-POLARIS approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover could cause severe injury or death.
  • Page 12 SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning (500 Midsize) WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. Maximum Box Load 500 lbs. (227 kg) IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

  • Page 13: Safe Riding Gear

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • 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 have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 16: Equipment Modifications

    The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

  • Page 17: Seat Belts

    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. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.

  • Page 18: Handling Gasoline

    SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times.

  • Page 19: Exposure To Exhaust

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

  • Page 20: 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 35. 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 21: Features And Controls

    FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets. Not all models come with all features.

  • Page 22: Gear Selector

    FEATURES AND CONTROLS Console Auxiliary Outlet Mode Instrument Storage Cluster Button Compartment The 12-volt receptacle has 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 con- sole, under the hood.
  • Page 23 FEATURES AND CONTROLS Switches AWD/Differential Switch Ignition Switch Light Switch 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. LIGHTS ON Lights are on.

  • Page 24: Trailer Hitch Bracket

    FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equip- ment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities out- lined on pages 38-39.

  • Page 25: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats. Always make sure the seat belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious Latch Plate injury or death.
  • Page 26 Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized Polaris dealer. Securing a Net 1.

  • Page 27: Storage Compartments

    Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

  • Page 28: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster The instrument cluster measures Speedometer distance traveled by the vehicle, as well as time, hours of opera- Speedometer tion and engine RPM. Needle Tip: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condi- tion exists.

  • Page 29: Rider Information Center

    Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear shifter position.

  • Page 30: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 18. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
  • Page 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
  • Page 32 When the display stops flashing, the mode has been set. Accessing Blink Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 29 for Blink Codes and Failure Descriptions. Use the following procedure to access blink codes (failure codes) from the EFI module.
  • Page 33 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Blink Code Descriptions Blink Failure Description Code No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground...

  • Page 34: Operation

    Break-In Period The break-in period for your new POLARIS RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period.

  • Page 35: Pre-Ride Inspection

    Ensure operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Belts...

  • 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. Secure the cab nets. 3. Apply the brakes. Place the transmission in PARK. 4. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START.

  • Page 37: Driving With A Passenger

    OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Sit in the driver's seat and fasten the seat belt. 3. Start the engine and allow it to warm 4. Always use the cab nets while riding in this vehicle.

  • Page 38: 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. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.

  • Page 39: 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. 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slip- 15°...

  • Page 40: Driving Through Water

    OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: 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. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 56, and take the vehicle to your dealer at the first opportunity.

  • Page 41: 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 42: 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 43: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta- bility. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2.
  • Page 44 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 differential. Press the top of the rocker switch to engage All Wheel Drive (AWD).

  • Page 45: 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 automati- cally disengage.

  • Page 46: Emission Control Systems

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

  • Page 47: Maintenance

    D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

  • Page 48: Periodic Maintenance Chart

    Inspect; adjust; replace as needed Cooling system (if applicable) 50 H Inspect coolant strength seasonally; pressure test system yearly Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. D Have an authorized POLARIS dealer perform these services.

  • Page 49: Lubrication Recommendations

    Chart beginning on page 43, 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. Item Lube Method Engine Oil POLARIS PS-4 PLUS Performance See page 46. Synthetic 2W-50 4-cycle Oil Brake Fluid DOT 4 See page 60.

  • Page 50: Engine Oil

    POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4- cycle oil or a similar oil. See page 76 for the part numbers of POLARIS products. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil.

  • Page 51: 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 43. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.
  • Page 52 MAINTENANCE Engine Oil Oil and Filter Change 11. Reattach the oil line. 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

  • Page 53: Gearcase Specification Chart

    Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 76 for the part numbers of POLARIS products. Oil Check The fill plug is located on the rear of the gearcase. A level check/alternate fill plug is located on the side of the gearcase.
  • Page 54 Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capaci- ties and torque specifications. See page 76 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

  • Page 55: Spark Plugs

    Refer to the specifications section beginning on page 74 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. Spark Plug Gap/Torque Model...

  • Page 56: Cooling System

    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. POLARIS Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 76 for the part numbers of POLARIS products.

  • Page 57: Radiator Coolant Level

    Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer. Radiator Coolant Level...
  • Page 58 • See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 59: Pvt Drying

    MAINTENANCE POLARIS Variable Transmission (PVT) System 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. 2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

  • Page 60: 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, follow the steps outlined below.

  • Page 61: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. 1.

  • Page 62: Spark Arrester

    MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. •...

  • Page 63: Throttle System

    Freeplay should be 1/16 to 1/8 inches (1.6-3.2 mm). 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 lower seat base.

  • Page 64: 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 20. 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 65: Steering Wheel Inspection

    3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer. Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension.

  • Page 66: 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.

  • Page 67: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 3. Attach the wheel nuts and washers and fin- ger tighten.

  • Page 68: Headlight Lamp Replacement

    Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be work- ing properly, please see your POLARIS dealer. Fuse Feature Supported...

  • Page 69: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 70 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 71: 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 72: Battery Installation

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 69. POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the bat- tery if the voltage drops below a pre-determined point.
  • Page 73 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electro- lyte during charging. See page 67. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rat- ing.

  • Page 74: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 75: Storage Tips

    Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. 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 76 5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline.

  • Page 77: Removal From Storage

    3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 31. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page Transporting the RANGER Follow these procedures when transporting the vehicle.

  • Page 78: Specifications

    SPECIFICATIONS RANGER 500 Midsize RANGER CREW 500 Maximum Weight Capacity 1000 lbs. (454 kg) 1250 lbs. (567 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1055 lbs. (478.5 kg) 1300 lbs. (589.7 kg) Fuel Capacity 8.8 gal. (33.3 l) 8.8 gal.
  • Page 79 Hood Headlights 2 single beam, 50W, quartz/halogen 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) 10 L.E.D. (3.1W) Indicator Light 1.0 W 1.0 W Clutching See your POLARIS dealer for clutching specifications.

  • Page 80: Polaris Products

    Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel 2872073 Chain Lube, Aerosol (6.25 oz.) 2872348 Chain Lube, Aerosol (16 oz.) Additives / Miscellaneous 2871326 Carbon Clean Plus 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger...

  • Page 81: Troubleshooting

    Dry out the PVT. See page 55. Inspect clutch seals for damage if repeated ingestion into the PVT system leaking occurs. Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. See your dealer.
  • Page 82 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 83 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 84: Warranty

    LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war-...
  • Page 85 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.
  • Page 86 If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty regis- ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 87 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. Environmental Protection Agency emission reg- ulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.
  • Page 88 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 products. THE REMEDIES SET FORTH IN THIS LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

  • Page 89: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 90 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 91: Index

    INDEX Accessory Outlets ......18 Coolant Level, Overflow Bottle ....53 Adjustments Coolant Level, Radiator .
  • Page 92 INDEX Fastener Torque, Cylinder Head/Base..56 Idle Speed ....... 59 Filter Systems .
  • Page 93 Stopping the Engine ..... . . 32 Polaris Products ......76 Storage .

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