Polaris RANGER 400 Owner's Manual
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Polaris RANGER 400 Owner's Manual

Maintenance and safety
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PMS 419
RANGER® 400
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris RANGER 400

  • Page 1 PMS 419 RANGER® 400 Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS®, RANGER® and RANGER CREW® are registered trademarks of POLARIS Industries Inc. Copyright 2013 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 5: Table Of Contents

    Maintenance ........52 POLARIS Products........85 Specifications .

  • Page 6: Introduction

    INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
  • Page 7 Failure to follow the warnings contained in this manual can result in severe injury or death. Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. 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 8: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
  • Page 9 INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

  • Page 10: Safety

    Helmet Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 11 Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs.
  • Page 12 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 13 SAFETY Safety Labels and Locations Seat Belt/Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use vehicle cab nets and/or doors. •...

  • Page 14: Clutch Cover Warning

    SAFETY Passenger/Tire Pressure Warning WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...

  • Page 15: Operator Safety

    SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described.
  • Page 16 • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.

  • Page 17: Equipment Modifications

    FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800-342-3764. Equipment Modifications Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

  • Page 18: Age Restrictions

    SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.
  • Page 19 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle.

  • Page 20: Handling Gasoline

    SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks. •...

  • Page 21: Operating On Public Roads

    SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

  • Page 22: Improper Tire Maintenance

    SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets (or doors).

  • Page 24: Component Locations

    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 console, under the hood.

  • Page 25: Brake Pedal

    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.
  • Page 26 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 position. The engine is off. Electrical circuits are off, except Acc, 12V.

  • Page 27: Trailer Hitch Bracket

    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.

  • Page 28: Seat Belt Inspection

    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 operating. 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.

  • Page 29: Seat Removal

    Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer. Securing a Net 1. After entering the vehicle, insert the lower net rod into the net mount on the floor. Make sure the ball at the end of the rod is properly secured in the slot at the base of the mount.

  • Page 30: Operation

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

  • Page 31: Pre-Ride Inspection

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

  • Page 32: Starting The Engine

    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 (or doors). 4. Apply the brakes. Place the transmission in PARK. 5.

  • Page 33: Stopping The Engine

    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.

  • Page 34: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 29. 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.

  • Page 35: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 36: Driving On Slippery Surfaces

    OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.

  • Page 37: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

  • Page 38: Parking On An Incline

    4. Block the rear wheels on the downhill side. 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.

  • Page 39: Hauling Cargo

    Never exceed the following capacities. Maximum Capacities Model Cargo Box (Level Ground) RANGER 400 1000 lbs. (454 kg) 500 lbs. (227 kg) WARNING! Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box.

  • Page 40: Towing Loads

    Vertical Towing (Level Ground) (15° grade) Weight Speed RANGER 400 1250 lbs. (567 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h) Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

  • Page 41: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Place the transmission in PARK. Dismount the vehicle. 4.
  • Page 42 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. Press the top of the rocker switch to engage All Wheel Drive (AWD).

  • Page 43: Disengaging Awd

    OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

  • Page 44: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

  • Page 45: Winch Safety Precautions

    WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15.

  • Page 46: Winch Operation

    WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 47 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 48 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object.
  • Page 49 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 50: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 51 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 52: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 53: Emission Control Systems

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

  • Page 54: Maintenance

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

  • Page 55: Periodic Maintenance Chart

    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.
  • Page 56 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.

  • Page 57: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method...

  • Page 58: Polaris Products

    POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil. See page 85 for the part numbers of POLARIS products. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

  • Page 59: Engine Oil

    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 52. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.

  • Page 60: Oil Pump Priming

    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.

  • Page 61: Specifications

    Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 85 for the part numbers of POLARIS products. Oil Check The fill plug is located on the rear of the gearcase. A level check/alternate fill plug is located on the side of the gearcase.
  • Page 62 Maintenance Chart beginning on page 52. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants, capacities and torque specifications. See page 85 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

  • Page 63: Spark Plugs

    Refer to the specifications section beginning on page 86 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark Plug Gap/Torque Model...

  • Page 64: Cooling System

    POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use. Do not dilute with water. See page 85 for the part numbers of POLARIS products.

  • Page 65: Radiator Coolant Level

    Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer. Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 52.
  • Page 66 • 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 67 MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

  • Page 68: Vehicle Immersion

    MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below.

  • Page 69: Filter Systems

    If present, drain them into a suitable container. 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.
  • Page 70 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.

  • Page 71: Spark Arrester

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

  • Page 72: Throttle System

    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.

  • Page 73: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 23. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 74: Steering Wheel Inspection

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

  • Page 75: Tire Tread Depth

    Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use POLARIS-approved size and type of tires for this vehicle when replacing tires. Tire Tread Depth Always replace tires when tread depth is 1/8"...

  • Page 76: Wheel Removal

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

  • Page 77: Headlight Beam Adjustment

    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. Do not operate this vehicle at night or in low light conditions until the headlight is replaced.

  • Page 78: Indicator Lamp Replacement

    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 harness. Be sure to pull on the connector, not on the wiring.
  • Page 79 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 80: Battery Removal

    MAINTENANCE Battery Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1.
  • Page 81 Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 80. 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 battery if the voltage drops below a pre-determined point.
  • Page 82 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 78. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

  • Page 83: Cleaning And Storage

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

  • Page 84: Storage Tips

    Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 85 5. Treat the fuel system with POLARIS Carbon Clean. See page 82. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

  • Page 86: Removal From Storage

    3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 29. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page Transporting the RANGER Follow these procedures when transporting the vehicle.

  • Page 87: Polaris Products

    2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) Grease / Specialized Lubricants 2871312 Grease Gun Kit, All Season Grease 2871322 All Season Grease (3 oz./89 ml cartridge)

  • Page 88: Specifications

    SPECIFICATIONS RANGER 400 Maximum Weight Capacity (includes weight of 1000 lbs. (454 kg) operator, passenger, cargo, accessories) Dry Weight 1050 lbs. (476 kg) Test GVW - Rollover Protection System (ROPS) 2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 8.8 gal.

  • Page 89: Clutching Chart

    SPECIFICATIONS RANGER 400 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Tire Pressure - Front 10 psi (68.9 kPa) Tire Pressure - Rear 12 psi (82.7 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc...

  • Page 90: Troubleshooting

    Dry out the PVT. See page 65. Inspect clutch seals for damage if repeated ingestion into the PVT system leaking occurs. Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. See your dealer.
  • Page 91 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...
  • Page 92 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
  • Page 93 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...

  • Page 94: Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 95 THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 96 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 97 SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location.
  • Page 98 30 calendar months from the date of purchase, whichever comes first. This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension.
  • Page 99 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 LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

  • Page 100: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 101 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 102 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 103: Index

    INDEX Accessory Outlet......22 Differential Lock Switch ....24 Air Filter .
  • Page 104 INDEX Fluid, Battery ......79 Lamp Replacement, Indicator Lights ..76 Fluid, Brake .
  • Page 105 INDEX Polaris Products ......85 Storage, Removal From ....84 Polishing the Vehicle .
  • Page 106 12 or who cannot comfortably reach the floor and hand holds. • 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 can cause severe injury or death.

This manual is also suitable for:

2014 ranger 400

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