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RANGER® 400 Midsize Owner's Manual for Maintenance and Safety...
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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.
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The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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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.
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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...
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POLARIS and RANGER 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.
Failure to follow the warnings contained in this manual can result in severe injury or death. A POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
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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.
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.
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• 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.
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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.
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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. •...
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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.
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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.
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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.
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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.
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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.
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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 30. 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.
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 passenger at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets.. ROPS Cab Frame Hip Bar...
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FEATURES AND CONTROLS Component Locations Indicator Gear Selector Storage Lights (Shifter) Compartment Storage 12V Auxiliary Holder Tray Outlet Auxiliary Outlet The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the con- sole, under the hood.
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FEATURES AND CONTROLS Component Locations Gear Selector Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads.
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FEATURES AND CONTROLS Switches Ignition Switch/Light Switch The ignition switch is a four-position, key- operated switch. The key can be removed from the switch when it is in the OFF posi- tion. The engine is off. Electrical circuits are off, except Acc, 12V.
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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 32-33.
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FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before oper- ating. Latch Plate The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.
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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.
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OSHA 1928.53 rollover ROPS Cab performance requirements. Always have your Frame 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.
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.
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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...
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OPERATION Starting the Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Turn the fuel valve on. 3. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 4. Apply the brakes. Place the transmission in PARK. 5.
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OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. WARNING! A rolling vehicle can cause serious injury. Always place the transmission in PARK when stopping the engine.
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OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 25. 2. Make sure any passenger is at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.
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OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the ter- rain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
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OPERATION 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. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slip- pery or loose surfaces.
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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 52, and take the vehicle to your dealer at the first opportunity.
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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.
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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.
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OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well venti- lated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
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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).
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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 trac- tion. 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.
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.
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.
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Inspect, lubricate, adjust D Steering 50 H Lubricate Front Suspension 50 H Lubricate Rear Suspension 50 H Lubricate Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. D Have an authorized POLARIS dealer perform these services.
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D Auxiliary brake (if equipped) Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. D Have an authorized POLARIS dealer perform these services.
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Main Gearcase Oil Premium AGL Synthetic Gearcase See page 45. (Transmission) Lube Front Gearcase Oil Demand Drive Plus Fluid See page 46. Front Prop Shaft Yoke POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum). Prop Shaft U-Joint...
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Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommenda- tions for ambient temperature operation. See page 71 for the part numbers of POLARIS products.
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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 38. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.
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MAINTENANCE Engine Oil Oil and Filter Change 14. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Make sure the gasket from the old filter is not still on the engine. 15.
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Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 71 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.
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Refer to the Gearcase Specifications Chart on page 45 for recommended lubricants, capaci- ties and torque specifications. See page 71 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.
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Refer to the specifications section beginning on page 72 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...
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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 71 for the part numbers of POLARIS products.
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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 Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 38.
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• 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.
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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.
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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.
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If present, drain them into a suitable con- tainer. 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. Breather Filter and Hoses 1.
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MAINTENANCE Carburetor 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 is 1200 +/- 200. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is unsatisfactory and all other conditions are favorable, the carburetor can be adjusted.
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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. Remove any combustible materials from the area.
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MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
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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.
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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 counter-clockwise to increase or decrease spring tension.
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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.
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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 finger tighten.
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MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
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MAINTENANCE Lights Headlight Lamp Replacement 1. Open the hood. Wiring Harness CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 2. Unplug the headlamp from the wiring har- ness. Be sure to pull on the connector, not on the wiring.
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MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
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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.
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Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 66. 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.
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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 64. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rat- ing.
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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.
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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.
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5. Treat the fuel system with POLARIS Carbon Clean. See page 68. If POLARIS fuel sys- tem additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
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3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 25. 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.
Dry out the PVT. See page 51. 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.
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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 Overuse of choke Inspect, clean and/or replace spark plug Low battery voltage Recharge the battery to 12.8 VDC...
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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...
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TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect, clean and/or replace spark plug Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires...
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-...
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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.
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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.
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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.
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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.
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