WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 23 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 52 MAINTENANCE AND LUBRICATION . . . . . . . . . 53 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . 99 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers and key number in the spaces provided. 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.
Operator Safety SAFETY WARNING 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.
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. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Operator Safety 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 procedures described. S Never allow anyone without a valid driver’s license to operate this vehicle. S Minimum age recommendation for passengers is five years old.
SAFETY Operator Safety S Always follow proper procedures for turning as described in this manual. 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. Practice on smaller hills before attempting larger hills.
Operator Safety SAFETY S Never modify this vehicle through improper installation or use of accessories. S Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. S Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.
SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed.
Operator Safety 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. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brakes gradually. When fully stopped, engage the park brake.
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. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.
Operator Safety 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. WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment.
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 WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving.
Operator Safety 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. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle 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 vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.
Operator Safety 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. CAUTION Always keep combustible materials away from the exhaust system.
SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection. Read and follow the instructions of the decals on the RANGER carefully. If any of the decals depicted in this manual differ from the decals on your 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.
Safety Decals and Locations SAFETY WARNING S VEHICLE ROLLOVER could cause severe injury or death. This cab frame is not designed or intended to provide rollover protection. S ALWAYS WEAR YOUR SEAT BELT for maximum protection. 7172676 Location 2 Location 3 (inside front of box) Container/Passenger/Tire Pressure Warning Decal Text Remove flammable material containers from box before filling. S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers in cargo box.
SAFETY Safety Decals and Locations 5 Location 5 (under hood) 6 ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.
SAFETY Safety Decals and Locations Discretionary Warning Decal 7 8 21
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. Do not over fill the tank. Do not fill the tank neck.
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 4 2 3 5 6 7 10 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
FEATURES AND CONTROLS Component Locations 12 15 14 12. 13. 14. 15.
FEATURES AND CONTROLS Component Locations 18 17 16 16 19 22 20 16. 17. 18. 19. 20. 21. 22.
FEATURES AND CONTROLS Indicator Lights 1. 2. 3. 4. 5. 6. High Gear Low Gear Neutral Gear Reverse Gear High Temperature Park Brake Trailer Hitch Bracket 6 2 4 5 3 1 This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on page 48.
FEATURES AND CONTROLS Fuel Cap/Fuel Gauge The fuel tank filler cap (8) is located on the right-hand side of the vehicle near the passenger seat. It has a built-in fuel gauge that indicates the amount of fuel remaining in the tank. When the indicator needle nears the E (empty) mark, refuel at the earliest opportunity. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.
FEATURES AND CONTROLS Seat Belts The RANGER is equipped with lap-style seat belts for the operator and passenger. WARNING Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER. Passengers under five years of age require special restraints, which are not available with this vehicle. No person under the age of five years may ride in the RANGER. To wear the seat belt properly, follow this procedure: 1.
Console 2 1 FEATURES AND CONTROLS 3 4 5 6 1 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
FEATURES AND CONTROLS Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: H L N R Low gear is the primary driving range for the RANGER XP. High gear is intended for use on hard-packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
Switches FEATURES AND CONTROLS Ignition Switch (1) The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF Engine off. All electrical circuits are off except Acc. 12V. 2 3 ON/RUN Electrical circuits are on. Electrical equipment can be used. START Electric starter is engaged by holding ignition switch key in this position. Upon release, the key will return to the ON/RUN position.
FEATURES AND CONTROLS Brake Pedal (1) Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. 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. Make sure there’s adequate throttle pedal freeplay. See page 81 for throttle pedal adjustment procedures.
Vehicle Break-In Period OPERATION 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. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.
Starting the Engine OPERATION 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. 1. 2. 3. 4. Sit in the driver’s seat and fasten the seat belt. Engage the park brake. Shift the transmission to neutral. Apply the brakes while starting the engine. NOTE: Do not press the throttle pedal while starting the engine. 5. Turn the ignition key past the ON/RUN position to START.
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Engage the park brake. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 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.
Driving Safely OPERATION Driving Procedures 1. Sit in the driver’s seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the service brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the park brake. 5. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 6. Drive slowly.
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. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. 4.
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. Always check the terrain carefully before climbing a hill. Braking and handling are greatly affected when operating in hilly terrain.
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). Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brakes slightly to aid in slowing.
Driving Safely OPERATION Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. 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). Follow these procedures when operating through water: 1. Always determine water depths and current before entering. 2.
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. Not all obstacles are immediately visible. Reduce speed and travel with caution in unfamiliar terrain.
Driving Safely OPERATION 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. Always inspect left and right fields of vision before backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
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. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine.
Driving Safely 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: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Maximum Capacities (Level Ground) Cargo Box RANGER 4X4 XP 1500 lbs. (681 kg) 1000 lbs. (454 kg) RANGER 6X6 EFI 1750 lbs. (794 kg) 1250 lbs. (567 kg) WARNING Driving with passengers in the cargo box can result in severe injury or death.
Driving Safely OPERATION 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. Never operate this vehicle with the cargo box in the raised position. 1. Select a level site to dump the cargo box.
OPERATION Driving Safely 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. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 45. Towing a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle.
Driving Safely OPERATION Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. 2. 3. 4. Stop the vehicle on a level surface. Turn the engine off. Engage the park brake. Remove the ignition switch key to prevent unauthorized use. WARNING Gasoline is extremely flammable and can be explosive under certain conditions.
OPERATION Differential Lock (4X4) The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. It’s beneficial to lock the differential in low traction situations. Move the AWD/Differential Lock rocker switch to the center position (A) to lock the differential and return to 2WD. Press the bottom of the switch (B) to unlock the differential and return to 1WD.
All Wheel Drive (AWD) OPERATION 1 The illuminated amber AWD switch (1) indicates that the vehicle is in AWD. When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. When the RANGER 6X6 AWD switch is off, the vehicle is in two-wheel drive at all times.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. 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.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " E J Perform these procedures more frequently for vehicles subjected to severe use. Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks " Engine breather 25 H Monthly -- Inspect; replace if necessary " Engine oil change 25 H 1M -- Perform a break-in oil change at one month " General 50 H 3M -- Lubricate all fittings, pivots, cables, etc.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) J Fuel system 100 H 12 M -- J Fuel filter 100 H 12 M -- " Radiator 100 H 12 M -- Inspect; clean external surfaces " Cooling hoses 100 H 12 M -- Inspect for leaks " Engine mounts 100 H 12 M -- Inspect 100 H 12 M -- Inspect J Spark plug 100 H 12 M -- Inspect; replace as needed J Ignition Timing 100 H 12 M -- Inspect " Wiring 100 H
MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More often under severe use, such as wet or dusty conditions F No.
MAINTENANCE AND LUBRICATION Lubrication Recommendations 6X6 (1) 4X4 6X6 6X6 4X4 6X6 (2) 6X6 (3) 59
MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
MAINTENANCE AND LUBRICATION Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil dipstick and fill tube (1) is located on the engine. 1. Position the vehicle on a level surface. 2. Apply the brakes. Start the engine and let it idle for 20-30 seconds, then stop the engine. 1 3. Lift the lever lock (2) to remove the dipstick.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 12. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil. 13. Shift the transmission to neutral. 14. Engage the park brake. 15. Apply the brakes. Start the engine. Allow it to idle for one to two minutes. 16. Stop the engine. Inspect for leaks. 17. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 18. Dispose of used filter and oil properly.
MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom of the fill plug hole. The fill plug (1) is located at the rear of the vehicle. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. Oil Check 1 1.
MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Oil Change The drain plug (2) is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. Drain the oil. Dispose of used oil properly. 3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings. 4. After the oil has drained completely, install a new sealing washer. 5.
MAINTENANCE AND LUBRICATION Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. The front gearcase fill plug (1) is located on the right side of the front gearcase. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications.
MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase (RANGER 6X6) Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products.
MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. The rear gearcase fill plug (1) is on the driver’s side of the rear gearcase.
MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan under the drain plug (2). Remove the drain plug. 3. Drain the oil. Dispose of used oil properly. 4. Clean the drain plug. Reinstall the drain plug. Torque to specification. 5. Add the recommended oil. 6. Reinstall the fill plug. Torque to specification. 7. Check for leaks.
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 4X4 XP .035″ (.9 mm) 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm) RANGER 6X6 EFI .035″ (.9 mm) 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm) Spark plug condition is indicative of engine operation.
MAINTENANCE AND LUBRICATION Spark Plugs 2. Wet Fouled The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil or incorrect throttle body adjustments. Spark Plug Removal and Replacement 1. Remove the seat to access the engine compartment. 2. Remove the spark plug cap.
MAINTENANCE AND LUBRICATION Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE AND LUBRICATION Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.
MAINTENANCE AND LUBRICATION Cooling System Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 1. Lift the hood and slowly remove the radiator cap (1). 2. View the coolant level through the opening. 3.
MAINTENANCE AND LUBRICATION Polaris Variable Transmission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.). When To Use Low Range vs. High Range Following is a guideline for when to use low range and high range.
MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE AND LUBRICATION 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. Loosen the bottom screws that secure the clutch cover. 2. Allow the water to drain. 3. Tighten the screws. 4. Apply the brakes. Start the engine. 5. Engage the park brake. 6. Shift the transmission to neutral. 7. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Lift the cargo box to access the air box. 1 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter (1). 4. Do not attempt to clean the main element. Install a new air filter.
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. Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging.
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. Immediately contact your dealer for service if throttle problems arise.
MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Adjustment 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved. NOTE: While adjusting, flip the throttle lever back and forth. 3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of adjuster. 1 2 3 1 Throttle Body/Idle RPM Idle RPM is preset by the manufacturer.
MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 32. 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. Change the brake fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.
Brakes MAINTENANCE AND LUBRICATION 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. 9. Change pads when worn to 3/64″ (1 mm). 3/64″ (1 mm) Park Brake Inspection 1. Slowly push the park brake pedal down with your foot. 2. After 8 to 12 clicks of pedal travel, check the vehicle for movement.
MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play. 4.
MAINTENANCE AND LUBRICATION Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it’s securely latched. 2. Push the red button in the middle of the buckle to make sure it releases freely. 3. Check the belt webbing for wear, cuts or damage.
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 mm) 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. Always maintain proper tire pressure.
Tires MAINTENANCE AND LUBRICATION WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. 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. Engage the park brake. 2. Loosen the wheel nuts slightly. 3.
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. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin.
Lights MAINTENANCE AND LUBRICATION 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. Apply the brakes. Start the engine. Turn on the headlights. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8″ (20.3 cm) below the mark placed on the wall in step 2.
MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2 2. Reach in behind the console 1 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. 4. Using a screwdriver, turn the light that needs to be replaced 1/4 turn counterclockwise. 5. Grip the light with a needle nose plier and remove the light from the assembly. 6.
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. 1. Move the vehicle to dry land or at the very least, to water below the footrests. 2. Dry any water present in the air box.
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. Be careful not to allow cleaning solution or tap water into the battery. WARNING Battery electrolyte is poisonous. It contains sulfuric acid.
Battery MAINTENANCE AND LUBRICATION 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 1 upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery. WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death.
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. Avoid skin contact with electrolyte as severe burns could result. 3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 99 for the part numbers of Polaris products. Cleaning the RANGER Keeping your RANGER clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your RANGER can be cleaned much like an automobile. Washing the RANGER The best and safest way to clean your RANGER is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make necessary repairs and then clean the vehicle thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use dish soap type cleaners only.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the injectors. Turn the engine off. 2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug holes, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
MAINTENANCE AND LUBRICATION Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it’s not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 34.
POLARIS PRODUCTS Part No. Description 2870791 2871281 2871844 Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2873602 2873603 2871653 2872276 2870465 2871654 2872277 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (qt.) Premium AGL Synthetic Gearcase Lube (gal.) Premium ATV Angle Drive Fluid (8 oz.) Premium ATV Angle Drive Fluid (2.5 gal.
SPECIFICATIONS RANGER 4X4 XP Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 100 2750 lbs. (1247 kg) 1185 lbs.
SPECIFICATIONS RANGER 4X4 XP Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: Pressurized Wet Sump 0W/40 PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R) 8.71:1 5.94:1 3.14:1 3.83:1 3.
SPECIFICATIONS RANGER 6X6 EFI Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Min. Turning Radius Cargo Box (L x W x H) Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Lubrication System Engine Oil 102 2900 lbs. (1317 kg) 1410 lbs. (640 kg) 8 gal. (30.
SPECIFICATIONS RANGER 6X6 EFI Front Suspension Center Suspension Rear Suspension Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Center/Rear Tire Pressure - Front Tire Pressure - Center/Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: MacPherson strut w/6.25 in. (15.9 cm) of travel Independent w/5.25 in. (13.
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 Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs 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 Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel 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 Check all connections and tighten Low battery voltage Recharge battery to 12.
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris RANGER against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
WARRANTY California Emission Control Warranty Statement The Air Index of this Engine is 3 0 2 Most Clean 4 6 8 10 Least Clean Note: The lower the Air Index, the less pollution. This engine is certified to be emission compliant for 1000 hours of use. Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc.
WARRANTY California Emission Control Warranty Statement 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 “Owner’s Manual”). POLARIS recommends that you retain all receipts covering maintenance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold start enrichment system, if applicable. (iv) Regulator assy (gaseous fuel, if applicable) (2) Air Induction System (i) Intake manifold, if applicable (ii) Air filter (3) Ignition System (i) Spark plugs.
WARRANTY What is Not Covered Under This Warranty This warranty does not cover any emission-related part which malfunctions, fails or is damaged due to alterations and/or modifications such as changing, adding or removing parts. 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.
WARRANTY Maintenance Schedule Key Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 117
INDEX A Age Restrictions . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive (AWD) . . . . . . . . . . Auxiliary Outlet . . . . . . . . . . . . . . . . AWD Switch . . . . . . . . . . . . . . . . . . . E 5 78 51 26 31 B Battery . . . . . . . . . . . . . . . . . . . . . 92-94 Battery Fluid . . . . . . . . . . . . . . . . . . . 93 Battery Installation . . . . . . . . . . . . . . 94 Battery Removal . . . . . . . . . . . . . . . . 93 Battery Storage . . . .
INDEX N S Noise Emission Control System . . . . 52 Spark Plugs . . . . . . . . . . . . . . . . . . 70-71 Specifications . . . . . . . . . . . . . . 100-103 Starting the Engine . . . . . . . . . . . . . . 35 Steering Wheel Inspection . . . . . . . . 84 Stopping the Engine . . . . . . . . . . . . . 36 Storage . . . . . . . . . . . . . . . . . . . . . 95-97 Storage Tips . . . . . . . . . . . . . . . . . 96-97 Suspension Adjustment . . . . . . . . . . . 84 Switches . . . . . . . . . . . . . . . . . . . . . .
