WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
Copyright 2005 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 production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
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.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
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. S Read this manual and all labels carefully. Follow the operating pro- cedures described.
Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. S Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate this vehicle on hills too steep for the vehicle or for your abilities.
Gasoline is extremely flammable. See page 22 for refueling instruc- tions. S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764. SAFETY...
We are concerned for the safety of our customers and for the general public. Therefore, 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 purposes.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Lock the parking brake after fully stopped.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts...
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it’s in safe operating condition.
WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris RANGER. Even though a child may be within the age group for which some...
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
RANGER, always read and follow the instructions of the decals on the RANGER. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
Safety Decals and Locations WARNING Remove flammable containers from box before refueling. Location 4 (inside front of box) Fuel / Passenger Warning Decal Text Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers in cargo box.
SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS...
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.
SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.
FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Component Locations 1. Cab Frame (if equipped) 2. Hip Bar 3.
FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display: 1. High Gear 2. Low Gear (if equipped) 3. Neutral Gear 4. Reverse Gear 5. High Temperature 6. Brakes 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.
Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
FEATURES AND CONTROLS Console 1. Cup Holder 2. Indicator Lights 3. Shift Lever 4. Light Switch 5. AWD/Differential Switch (if equipped) 6. Hour Meter 7. Glove Box with Lid 8. 12V Accessory Plug 9. Storage Tray 10. Choke Knob 11. Ignition Switch 12.
Gear Selector (1) RANGER 2X4, 4X4 H: High Gear L: Low Gear N: Neutral R: Reverse RANGER TM H: High Gear N: Neutral R: Reverse NOTE: Low is the primary driving range for the RANGER 2X4 and 4X4. High is intended for use on hard-packed surfaces with light loads.
FEATURES AND CONTROLS Ignition Switch (1) 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.
FEATURES AND CONTROLS Brake Pedal (1) Depress the brake pedal to slow or stop the vehicle. Throttle Pedal (2) Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 22. 2. Check the oil level on the dipstick. See page 61. Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal (safe) operating range.
Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced OPERATION Page...
OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage.
Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface.
OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you’re familiar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.
5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission (PVT) shifting is automatic. 6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2.
Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15_ maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn.
OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15_ maximum).
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle.
Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6.
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury.
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: Always load the cargo box with the load as far forward as possible.
OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions.
Hauling Cargo Towing Loads WARNING Towing 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 towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.
OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3.
Differential Operation Modes The rear axle is equipped with a lockable differential. On AWD models, engaging AWD locks the front differential and the rear differential. CAUTION 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.
OPERATION All Wheel Drive (AWD) When in AWD, the front gearcase will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving.
The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
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 USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
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. Record maintenance and service in the Maintenance Log beginning on page 120.
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 result in component failure and lead to serious injury or death.
(if equipped) Transmission oil 25 H " Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride Pre-Ride Pre-Ride...
100 H " Valve clearance 100 H Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 25 H Monthly...
Auxiliary brake (if " equipped) Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 12 M...
More often under severe use, such as wet or dusty conditions " Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
MAINTENANCE AND LUBRICATION Lubrication Recommendations...
Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check (2x4, 4X4) The oil tank is located under the seat.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) CAUTION Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin. 1. Run the engine two to three minutes until warm. Stop the engine. 2.
14. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 15. Remove the dipstick and fill the tank with two quarts (1.9 l) of Polaris Premium 4 Synthetic Oil. 16. Place the gear selector in neutral and set the parking brake.
MAINTENANCE AND LUBRICATION Engine Oil Oil Pump Priming (2x4, 4X4) This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent line’s...
MAINTENANCE AND LUBRICATION Engine Oil Oil Check (TM) 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 27. Remove the service panel (1) by pulling upward.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 1. Position the vehicle on a level surface. 2. Run the engine two to three minutes until warm, then stop the engine. 3. Clean the area around the drain plug (6) at the bottom of the engine.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 7. Place shop towels beneath the oil filter (1). Using an oil filter wrench (2), turn the filter counterclockwise to remove. 8. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of Polaris Premium Demand Drive Hub Fluid. See page 101 for the part numbers of Polaris products.
Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of Polaris ATV Angle Drive Fluid. See page 101 for the part numbers of Polaris products.
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 101 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations...
MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.
MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model Electrode Gap RANGER .025″ (.06 cm)
Always follow all recommended maintenance procedures. 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.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle 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.
MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the gasket.
Always reinstall the breather filter after removing it for service. Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter.
MAINTENANCE AND LUBRICATION Filter Systems (TM) Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Remove the seat to access the air cleaner. 2. Remove the breather hose (1) from the cylinder.
MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. Recommended engine idle RPM for the RANGER TM is 1000 +/- 100.
MAINTENANCE AND LUBRICATION 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.
MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3.
MAINTENANCE AND LUBRICATION 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. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Inspection 1. Apply the parking brake (2) and shift the transmission to neutral. 2. Start the engine and warm it up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed.
MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation.
MAINTENANCE AND LUBRICATION 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.
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. Cylinder Head/Cylinder Base Fastener Torque Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.
3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passenger before driving.
MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake.
MAINTENANCE AND LUBRICATION Lights 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
MAINTENANCE AND LUBRICATION Lights Headlight Beam Adjustment 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. 3.
MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the console panel.
Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your Polaris dealer for free replacement. If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels.
MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder.
4. Check all the points listed in the Daily Pre-Ride Inspection section on page 33. NOTE: 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 53. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.
MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery.
MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.5 VDC...
WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma- terial or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
Manufacturer’s Warranty Coverage: The 2005 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner’s Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-...
During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.
When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
California Emission Control Warranty Statement Maintenance Schedule Item Hours Calendar Engine oil level " Air filter, pre-filter " Air box sediment " tube Air filter, " main element Engine breather " filter (if equipped) Engine oil change " (break-in) Throttle Cable/ ETC Switch Choke cable Carburetor air...
All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed.
Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.