Table of Contents
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Table of Contents
Related Manuals for Polaris Ranger 2005
Summary of Contents for Polaris Ranger 2005
- Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
- Page 5 Copyright 2004 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.
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Page 6: Welcome
S Sport Boats 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 vehicle we’ve ever produced. -
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: Table Of Contents
... . MAINTENANCE AND LUBRICATION ..POLARIS PRODUCTS ..... . SPECIFICATIONS . -
Page 10: 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 11: 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 12 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. S Read this manual and all labels carefully. Follow the operating pro- cedures described.
- Page 13 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 14 Gasoline is extremely flammable. See page 24 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.
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Page 15: 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 16 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 when fully stopped.
- Page 17 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 18 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 19 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 20 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 21 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 22 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.
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Page 23: Safety Decals And Locations
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 24 SAFETY Safety Decals and Locations WARNING WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. WARNING Maximum Box Load is ___ lbs. 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.
- Page 25 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 26 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...
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Page 27: 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 28: 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 100. Component Locations 1. Cab Frame (if equipped) 2. Hip Bar 3. -
Page 29: Component Locations
FEATURES AND CONTROLS Component Locations 10. Headlights 11. Radiator (if equipped) 12. Front Bumper/Brush Guard 13. Hood Hold Down Strap... - Page 30 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...
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Page 31: 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 32: Seat Removal
FEATURES AND CONTROLS 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 33 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.
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Page 34: Gear Selector
FEATURES AND CONTROLS Gear Selector (1) RANGER 4X4, 6X6 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 4X4 and 6X6. High is intended for use on hard-packed surfaces with light loads. -
Page 35: Ignition Switch
FEATURES AND CONTROLS Switches 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. Engine off. All electrical circuits are off except Acc. 12V. Electrical circuits are on. -
Page 36: 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 37: Operation
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 24. 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 38: Pre-Ride Inspection
Inspect, clean 77, 79 Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Brake light / tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced... -
Page 39: 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 40: Starting A Warm Engine
OPERATION 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 41 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.
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Page 42: 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 43: 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 44: Driving Uphill
OPERATION Driving Safely Driving Uphill 15_ Maximum 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 45: 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 46: 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 47: 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 48: Driving In Reverse
OPERATION 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 49: 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 50: Hauling Cargo
OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Always load the cargo box with the load as far forward as possible. -
Page 51: 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 52: Towing Loads
OPERATION 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 53: 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 54: All Wheel Drive (Awd)
OPERATION All Wheel Drive (AWD) Your Polaris RANGER (4X4 and 6X6) is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the console (1). When the switch is off, the RANGER is in two-wheel drive at all times. -
Page 55: Emission Control Systems
The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform. -
Page 56: Noise Emission Control System
Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved 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 57: Maintenance And Lubrication
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. -
Page 58: Periodic Maintenance Chart
Inspect level; change yearly " (if equipped) Transmission oil 25 H Monthly Inspect level; change yearly " Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. - Page 59 12 M Inspect routing, condition " Valve clearance 100 H 12 M Inspect; adjust Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
- Page 60 Auxiliary brake (if Inspect daily; adjust as " equipped) needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
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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...
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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 Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check (RANGER 4X4, 6X6) The oil tank is located under the seat.
- Page 65 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER 4X4, 6X6) 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 16. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 17. Remove the dipstick and fill the tank with two quarts (1.9 l) of Polaris Premium 4 Synthetic Oil. 18. Place the gear selector in neutral and set the parking brake.
- Page 67 MAINTENANCE AND LUBRICATION Engine Oil Oil Check (RANGER 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 29. Remove the service panel (1) by pulling upward.
- Page 68 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER TM) 5. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 6.
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Page 69: Gearcase Specification Chart
MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15.2 oz. 14 ft. lbs. 14 ft. lbs. (Transmission) Synthetic Gearcase (450 ml) (19.4 Nm) (19.4 Nm) (4X4, 6X6) Lube Main Gearcase Premium AGL 18.2 oz. -
Page 70: Oil Change
We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 99 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. -
Page 71: Oil Check
Periodic Maintenance Chart beginning on page 54. 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 99 for the part numbers of Polaris products. - Page 72 Periodic Maintenance Chart beginning on page 54. 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 99 for the part numbers of Polaris products.
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Page 73: Rear Gearcase
Periodic Maintenance Chart beginning on page 54. 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 99 for the part numbers of Polaris products. -
Page 74: Adding Or Changing Coolant
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 99 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations... -
Page 75: 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 76: Radiator Coolant Level
MAINTENANCE AND LUBRICATION Cooling System (RANGER 4X4, 6X6) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. -
Page 77: 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 100. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER 9-11 ft. -
Page 78: 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 79: 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 80: Air Filter
MAINTENANCE AND LUBRICATION Filter Systems (RANGER 4X4, 6X6) Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. 1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the gasket. -
Page 81: 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 82 8. Reassemble all components. 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.
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Page 83: 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 84 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.
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Page 85: 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 86 MAINTENANCE AND LUBRICATION Throttle System Throttle Cable Adjustment (RANGER TM) If the proper freeplay cannot be obtained with the throttle block adjuster, adjust the cable at the carburetor using the following procedure. 1. Remove the seat and loosen the clamp screw (1) and the throttle cable adjustment screw (2).
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Page 87: Brake Fluid
MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 33. 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 88: Brake Inspection
MAINTENANCE AND LUBRICATION Brakes Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear. -
Page 89: 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 90: 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 91: 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 92: Wheel Removal
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. -
Page 93: 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 94: 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 95: Indicator Lamp Replacement
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 96: 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 97 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.
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Page 98: Removal From Storage
4. Check all the points listed in the Daily Pre-Ride Inspection section on page 35. 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 54. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. - Page 99 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.
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Page 100: 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 101: 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 102: Polaris Products
POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) -
Page 103: Specifications
SPECIFICATIONS RANGER TM Gross Vehicle Weight 2400 lbs. (1089 kg) Fuel Capacity 8.5 gal. (32.2 l) Towing Capacity 1000 lbs. (454 kg) Max. Cargo Box Load 750 lbs. (340 kg) Overall Length 113 in. (282 cm) Overall Width (box) 60 in. (152.4 cm) Overall Width (tires) 58 in. - Page 104 4 wheel hydraulic disc Brake, Parking Foot activated, mechanical Hood Headlight 2 dual beam, 35W, quartz/halogen Taillights 2 single beam, 5W Brake Light 2 single beam, 5W Indicator Light 1.0 W NOTE: See your Polaris dealer for jetting and clutching specifications.
- Page 105 SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight 2700 lbs. (1226 kg) Fuel Capacity 8.5 gal. (32.2 l) Towing Capacity 1500 lbs. (681 kg) Max. Cargo Box Load 1000 lbs. (454 kg) Overall Length 113 in. (282 cm) Overall Width (box) 60 in. (152.4 cm) Overall Width (tires) 58 in.
- Page 106 4 wheel hydraulic disc Brake, Parking Foot activated, mechanical Hood Headlight 2 dual beam, 35W, quartz/halogen Taillights 2 single beam, 5W Brake Light 2 single beam, 5W Indicator Light 1.0 W NOTE: See your Polaris dealer for jetting and clutching specifications.
- Page 107 SPECIFICATIONS RANGER 6X6 Gross Vehicle Weight 2900 lbs. (1317 kg) Fuel Capacity 8.5 gal. (32.2 l) Towing Capacity 1500 lbs. (681 kg) Max. Cargo Box Load 1200 lbs. (544 kg) Overall Length 120 in. (304.8 cm) Overall Width (box) 60 in. (152.4 cm) Overall Width (tires) 58 in.
- Page 108 4 wheel hydraulic disc Brake, Parking Foot activated, mechanical Hood Headlight 2 dual beam, 35W, quartz/halogen Taillights 2 single beam, 5W Brake Light 2 single beam, 5W Indicator Light 1.0 W NOTE: See your Polaris dealer for jetting and clutching specifications.
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Page 109: 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 Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections... - Page 110 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...
- Page 111 Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...
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Page 112: 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 113 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 114 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...
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Page 115: Limited Warranty
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 116 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.
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Page 117: 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 118 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine oil level Pre-Ride Make adjustments as need- " ed. See Pre-Ride Checklist on page 35. Air filter, pre-filter Daily Inspect; clean often "...
- Page 119 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.
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Page 120: Index
INDEX Age Restrictions ....Electromagnetic Interference ..Air Filter ....77, 79 EMISSION CONTROL SYSTEMS... - Page 121 54-57 Throttle Pedal ....POLARIS PRODUCTS ..Throttle System ....