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Polaris 500 2X4 User Manual

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   Summary of Contents for Polaris 500 2X4

  • Page 3

    WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

  • Page 4

    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...

  • Page 5

    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.

  • Page 6: Table Of Contents

    ......EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION POLARIS PRODUCTS SPECIFICATIONS TROUBLESHOOTING WARRANTY .

  • Page 7: Vehicle Identification Numbers

    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.

  • Page 8: Safety

    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: Operator Safety

    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.

  • Page 10

    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.

  • Page 11

    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.

  • Page 12

    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...

  • Page 13: Equipment Modifications

    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.

  • Page 14

    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.

  • Page 15

    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.

  • Page 16

    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.

  • Page 17

    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...

  • Page 18

    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.

  • Page 19

    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...

  • Page 20

    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.

  • Page 21

    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.

  • Page 22

    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.

  • Page 23

    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...

  • Page 24

    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.

  • Page 25: Fuel Safety

    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.

  • Page 26: Features And Controls

    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.

  • Page 27: Component Locations

    FEATURES AND CONTROLS Component Locations 10. Headlights 11. Radiator (if equipped) 12. Front Bumper/Brush Guard 13. Hood Hold Down Strap...

  • Page 28

    FEATURES AND CONTROLS Component Locations 14. Taillights 15. Tailgate 16. Tailgate Latch Release 17. Muffler (Spark Arrester) 18. CV Boot/Rear Caliper 19. Air Box 20. Receiver Hitch...

  • Page 29: Indicator Lights

    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.

  • Page 30: Seat Removal

    Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

  • Page 31

    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.

  • Page 32: Gear Selector

    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.

  • Page 33: Ignition Switch

    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.

  • Page 34: Brake Pedal

    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.

  • Page 35: Operation

    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.

  • Page 36

    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...

  • Page 37: Starting The Engine

    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.

  • Page 38: Stopping The Engine

    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.

  • Page 39

    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.

  • Page 40: Driving Safely

    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.

  • Page 41: Driving On Slippery 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.

  • Page 42: Driving Uphill

    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.

  • Page 43: Driving Downhill

    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).

  • Page 44: Driving Through Water

    Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1).

  • Page 45: Driving Over Obstacles

    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.

  • Page 46: Driving In Reverse

    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.

  • Page 47: Parking On An Incline

    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.

  • Page 48: Hauling Cargo

    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.

  • Page 49: Dumping The Cargo Box

    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.

  • Page 50: Towing Loads

    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.

  • Page 51: Parking The Ranger

    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.

  • Page 52: Differential Operation Modes

    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.

  • Page 53: All Wheel Drive (awd)

    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.

  • Page 54: Emission Control Systems

    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.

  • Page 55: Noise Emission Control System

    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.

  • Page 56: Maintenance And Lubrication

    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.

  • Page 57: Periodic Maintenance Chart

    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.

  • Page 58

    (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...

  • Page 59: Maintenance Interval

    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...

  • Page 60

    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...

  • Page 61: Lubrication Recommendations

    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.

  • Page 62

    MAINTENANCE AND LUBRICATION Lubrication Recommendations...

  • Page 63: Engine Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40.

  • Page 64: Oil Check (2x4, 4x)

    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.

  • Page 65

    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.

  • Page 66

    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.

  • Page 67: Oil Pump Priming (2x4, 4x)

    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...

  • Page 68: Oil Check (tm)

    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.

  • Page 69

    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.

  • Page 70

    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.

  • Page 71: Gearcase Specification Chart

    MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Main Gearcase (Transmission) Synthetic Gearcase (4X4) Main Gearcase (Transmission) Synthetic Gearcase (2X4, TM) Front Gearcase Premium Demand (4X4) Rear Gearcase Premium ATV Angle (2X4, 4X4) Rear Gearcase Premium ATV Angle (TM) Lubricant Capacity Premium AGL 15.2 oz.

  • Page 72: Oil Change

    We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 101 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface.

  • Page 73: Front Gearcase (4x)

    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.

  • Page 74: Oil Check

    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.

  • Page 75

    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...

  • Page 76: Coolant Level

    Reinstall the cap. NOTE: 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.

  • Page 77: Radiator Coolant Level

    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.

  • Page 78: Spark Plugs

    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)

  • Page 79: Pvt Drying

    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.

  • Page 80: Vehicle Immersion

    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.

  • Page 81: Filter Systems (2x4, 4x)

    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.

  • Page 82: Fuel Filter

    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.

  • Page 83: Filter Systems (tm)

    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.

  • Page 84

    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.

  • Page 85: Spark Arrestor

    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.

  • Page 86

    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.

  • Page 87: Throttle System

    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.

  • Page 88: Throttle Cable Adjustment (tm)

    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.

  • Page 89: Brake Fluid

    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.

  • Page 90: Brake Inspection

    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.

  • Page 91: Steering Wheel Inspection

    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.

  • Page 92: Seat Belts

    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.

  • Page 93: Tire Tread Depth

    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.

  • Page 94: Wheel Installation

    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.

  • Page 95: Headlight Lamp Replacement

    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.

  • Page 96: Headlight Beam Adjustment

    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.

  • Page 97: Tool Kit

    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.

  • Page 98: Cleaning Your Ranger

    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.

  • Page 99

    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.

  • Page 100: Removal From Storage

    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.

  • Page 101

    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.

  • Page 102: Battery Removal

    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.

  • Page 103: Battery Installation

    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.

  • Page 104: Polaris Products

    60/40 Coolant (gal.) 2871323 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS...

  • Page 105: Specifications

    SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement...

  • Page 106

    Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for jetting and clutching specifications. SPECIFICATIONS RANGER TM Full Pressure 0W/40 Single Lever (console) 6.84:1 4.71:1 3.70:1...

  • Page 107

    SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement...

  • Page 108

    Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights/Brake Light Indicator Light NOTE: See your Polaris dealer for jetting and clutching specifications. SPECIFICATIONS RANGER 2x4 Dry Sump 0W/40 Single Lever (console) 8.71:1 5.9:1 3.83:1 3.70:1...

  • Page 109

    SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement...

  • Page 110

    Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for jetting and clutching specifications. SPECIFICATIONS RANGER 4X4 Dry Sump 0W/40 Single Lever (console) 8.71:1 5.9:1 3.83:1 3.83:1...

  • Page 111: Troubleshooting

    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...

  • Page 112

    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...

  • Page 113

    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...

  • Page 114: Warranty

    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...

  • Page 115

    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).

  • Page 116: How To Get Service

    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...

  • Page 117: California Emission Control Warranty Statement

    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-...

  • Page 118: Warranty Period

    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.

  • Page 119: Maintenance Schedule

    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.

  • Page 120

    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...

  • Page 121

    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.

  • Page 122

    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.

  • Page 123: Maintenance Log

    MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 124

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 125: Index

    INDEX Age Restrictions ....Air Filter (2x4, 4X4) ... . . Air Filter (TM) .

  • Page 126

    Parking the RANGER ... . Periodic Maintenance Chart Polaris Products ....Pre Ride Inspection ....

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