Polaris RANGER XP 900 Owner's Manual
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Polaris RANGER XP 900 Owner's Manual

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RANGER XP® 900
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Summary of Contents for Polaris RANGER XP 900

  • Page 1 RANGER XP® 900 RANGER CREW® 900 Owner's Manual for Maintenance and Safety...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • 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®, RANGER XP® and RANGER CREW® are trademarks of POLARIS Industries Inc. Copyright 2014 POLARIS Industries 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

    Specifications ........94 POLARIS Products........98 Troubleshooting .

  • Page 6: Introduction

    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 7 INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations con- cerning 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 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: Safe Riding Gear

    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 Maximum Occupant Capacity Warning (CREW 900) WARNING The maximum occupant seating for this vehicle is 5 passengers. Modification of the seating configuration may be considered a violation of federal law by the U.S. Environmental Protection Agency.

  • Page 14: Clutch Cover Warning

    Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner’s manual or see authorized POLARIS dealer. 7177469 Clutch Cover Warning...

  • 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

    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: Seat Belts

    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 and Doors 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 (or doors, if equipped) on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab nets (or doors). Not all models (or doors) are equipped with all features.

  • Page 24: Cab Heater (If Equipped)

    FEATURES AND CONTROLS Console Mode Instrument Button 12V Auxiliary Cluster Storage Outlets Compartment Ignition Switch Cup Holder Headlight AWD/ Differential Switch Lock Switch Cab Heater (if equipped) Driver’s Seat Passenger’s Seat Heater Switch Heater Switch To operate the cab heater, rotate the fan control to the desired fan speed setting.

  • Page 25: Gear Selector

    FEATURES AND CONTROLS Console Auxiliary Outlets 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 dash. Gear Selector Low gear is the primary driving range for the Gear Selector RANGER.

  • Page 26: Ignition Switch

    FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.

  • Page 27: Windshield Wiper And Washer (If Equipped)

    FEATURES AND CONTROLS Switches Windshield Wiper and Washer (if equipped) The windshield wiper and washer switches are located on the wiper motor centered above the windshield. The windshield washer fluid reservoir is located under the hood. Windshield Washer Fluid Reservoir Washer Wiper Switch...

  • Page 28: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Throttle Depress the brake pedal to slow or stop the vehicle. Apply Brake Pedal the brakes while starting the engine. Pedal Throttle Pedal Push the throttle 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 29 FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery. CREW models are equipped with a storage console and cup holders located between the front seats.

  • Page 30: Trailer Hitch Bracket

    The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 ROPS rollover performance requirements. Always have your 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 31 Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or dam- aged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer. Securing a Net Cab Net Latch 1.
  • Page 32 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured.

  • Page 33: Windshield (If Equipped)

    FEATURES AND CONTROLS Windshield (if equipped) If equipped, the windshield on your model may be a fixed windshield or a tip-out windshield. The tip-out windshield can be opened. Tip-Out Windshield The bottom edge of the tip-out windshield can be tipped away from the vehicle to a vent position or to a fully open position.
  • Page 34 FEATURES AND CONTROLS Rear Window Panel (if equipped) Window Removal 1. Rotate the upper window latches Latches counter-clockwise to release the locks. 2. Tilt the upper edge of the window slightly outward and free the lower window brackets from the frame, then carefully lift the window up and away from the vehicle.

  • Page 35: Instrument Cluster

    This indicator illuminates briefly when the key is turned to the ON equipped) position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 36 If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied.

  • Page 38: Rider Information Center

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to the odometer display.
  • Page 39 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 40 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See an authorized POLARIS dealer for code details and diagnosis.

  • Page 41: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER is the first 25 hours of operation, or the time it takes to use the first two tanks full of fuel.
  • Page 42 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it’s in safe operating condition. Item Remarks Page Brake system/pedal travel...

  • Page 43: Starting The Engine

    OPERATION Starting the Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors). 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the engine. 5.

  • Page 44: Driving Procedure

    OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection. See page 40. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets (or doors) while riding in this vehicle. 5.

  • Page 45: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 40. 2. Make sure all passengers are 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 46: 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 47: 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 48: Driving Through Water

    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 77, and take the vehicle to your dealer at the first opportunity.

  • Page 49: 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 50: Parking On An Incline

    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 ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 51: 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: 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, passengers, non-factory installed accessories, loads in the rack or box and the load on the trailer tongue.

  • Page 52: Towing Loads

    Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towing (Level Ground) (15° grade) Weight Speed RANGER XP 900 2000 lbs. 850 lbs. 150 lbs. 10 MPH (907 kg) (386 kg) (68.1 kg) (16 km/h) RANGER CREW 900 2000 lbs.

  • Page 53: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo Release Lever box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. Place the transmission in PARK. 3.

  • Page 54: Engaging Awd

    OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. See page 35. Differential Lock When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose Differential Unlock...

  • Page 55: Locking The Differential

    OPERATION All Wheel Drive (AWD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

  • Page 56: 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 57: 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 58: 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 59 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 60 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 61: Winch Cable Care

    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 62 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 63: 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 64: 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 65: 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 66: Periodic Maintenance Chart

    ► Front Suspension 50 H 500 (800) Lubricate ► Rear Suspension 50 H 500 (800) 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 67 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 68: Lubrication Recommendations

    Periodic Maintenance Chart. Oil Recommendations POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the specifications section beginning on page 94 for capacities. See page 98 for the part numbers of POLARIS products.

  • Page 69: Oil Check

    MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components.
  • Page 70 MAINTENANCE Engine Oil Oil and Filter Change 3. Place the transmission in PARK. 4. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box. 5. Locate the crankcase drain plug access hole in the skid plate. 6.

  • Page 71: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart RANGER XP 900/RANGER CREW 900 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase AGL Gearcase 40.6 oz. 12 ft-lbs 12 ft-lbs (Transmission) (1200 ml) (16.3 Nm) (16.3 Nm) Lubricant &...
  • Page 72 Refer to the Gearcase Specifications Chart on page 69 for recommended lubricants, capaci- ties and torque specifications. See page 98 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 73: Spark Plugs

    Refer to the specifications section beginning on page 94 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 Electrode Gap...

  • Page 74: Cooling System

    Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle. Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 98 for the part numbers of POLARIS products.

  • Page 75: Radiator Coolant Level

    Have the cooling system inspected by your POLARIS dealer. Radiator Coolant Level 1. Remove the hood. See page 28. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot.
  • Page 76 • 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 77 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 5. Make sure the cover gasket does not fall out of the groove when removing the cover. 6. Squeeze the belt together so that it submarines further into the driven clutch, creating slack in the belt between the clutches.
  • Page 78 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it. 10. Remove all debris wrapped in and around the PVT system.

  • Page 79: Vehicle Immersion

    MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine.

  • Page 80: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on Air Box Latches page 63. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle Filter for extended periods.

  • Page 81: 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 clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Allow components to cool sufficiently before proceeding.

  • Page 82: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 26. 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. Never store or use a partial bottle.

  • Page 83: Brake Inspection

    3. Lightly turn the steering wheel left and right. 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.

  • Page 84: Suspension Adjustments

    MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting positions. 2. Reposition the shocks to the outside mounting holes. 3. Reinstall the shock mounting bolts. Torque to 40 ft-lbs (54.2 Nm). Outside Mounting Position Inside Mounting Position...

  • Page 85: 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 86: 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 fin- ger tighten.

  • Page 87: Headlight Lamp Replacement

    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 88: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 89 The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.

  • Page 90: Battery Removal

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 89. 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.

  • Page 91: Battery Charging

    MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.

  • Page 92: 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 93: 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 94 5. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs. 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines and injectors should be completely drained of gasoline.

  • Page 95: 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 40. 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 96: Specifications

    SPECIFICATIONS RANGER XP 900 Maximum Weight Capacity 1500 lbs. (681 kg) (4X4) (including operator, passenger, 1100 lbs. (499 kg) (4X4 sold in California) cargo, non-factory installed 1275 lbs. (578 kg) (4X4 Hunter/NorthStar) accessories) 875 lbs. (397 kg) (4X4 Hunter/NorthStar sold in California) Dry Weight 1360 lbs.
  • Page 97 Tire Pressure - Rear 12 psi (83 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.
  • Page 98 SPECIFICATIONS RANGER CREW 900 Maximum Weight Capacity 1750 lbs. (795 kg) (including operator, passengers, cargo, accessories) 1350 lbs. (612 kg) (Models sold in California) Dry Weight 1570 lbs. (712 kg) Test GVW - Rollover Protection 3600 lbs. (1633 kg) per OSHA 29 CFR 1928.53 System (ROPS) Fuel Capacity 10 gal.
  • Page 99 Tire Pressure - Rear 16 psi (110 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.

  • Page 100: Polaris Products

    U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 101: Troubleshooting

    Dry out the PVT. See page 77. 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 gas tank or fuel lines. See your dealer.
  • Page 102 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 Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 103 TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel...

  • Page 104: 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 105 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 106 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 107 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 108 *As related to the evaporative emission control system. 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 109: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 110 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 111: Index

    INDEX Air Filter ....... . 78 Differential Lock Switch ....24 Air Filter Cleaning .

  • Page 112: Oil Change

    Plugs, Spark ......71 Polaris Products ......98 Ignition Switch.
  • Page 113 INDEX Safety Labels......10-12 Tachometer ......37 Safety Symbols .
  • Page 114 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.

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