PMS 419 RANGER 800 XP RANGER 800 HD RANGER 800 6X6 RANGER 800 CREW Owner's Manual for Maintenance and Safety
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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees. • On public roads, a collision can occur with another vehicle. • With more than two passengers (five for CREW), or passengers under age twelve or who cannot comfortably reach the floor and hand holds. • On paved surfaces - pavement may seriously affect handling and control.
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. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER® utility vehicles • Victory Motorcycles® • Low Emission Vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS, THE WAY OUT, RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc. Copyright 2011 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Maintenance . . . . . . . . . . . .
INTRODUCTION 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. • Read this owner’s manual.
INTRODUCTION 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. 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.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. 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.
SAFETY Safety Labels and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees 15. • On public roads, a collision can occur with a another vehicle. • With more than two passengers (five for CREW), or passengers under age twelve or who cannot comfortably reach the floor and hand holds.
SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning 6x6 Storage Box Load 250 lbs. (113 kg) WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothing for comfort and to reduce the chance of injury. 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. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY Operator Safety • Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. • Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill.
SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a POLARIS RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license.
SAFETY Operator Safety Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities.
SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds. Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn.
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab nets. Not all models come with all features. Refer to the specifications section on page 78.
FEATURES AND CONTROLS Console Park Brake Lever Gear Selector (Shifter) 12V Auxiliary Outlets Instrument Cluster Storage Storage Tray Compartment Cup Holder 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. On CREW models, an additional receptacle is located on the rear of the driver’s seat.
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. OFF The engine is off. Electrical circuits are off, except Acc, 12V. ON Electrical circuits are on. Electrical equipment can be used. START Turn the key to the START position to engage the electric starter. The key returns to the ON position when released.
FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 37-38. Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Brake Pedal Throttle Pedal Throttle Pedal Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released.
FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1300 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.
FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets. Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats.The center seat is equipped with a lap-style seat belt.
FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 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. WARNING! Vehicle rollover could cause severe injury or death.
FEATURES AND CONTROLS Instrument Cluster Speedometer High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Indicator Lamps Speedometer The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 26.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is 2 located in the instrument cluster. All segments will light up for one second at start-up. If the instrument E F cluster fails to illuminate, a battery RPM Trip 1 over-voltage may have occurred 1 and the instrument cluster may have 3 shut off to protect the electronic km mi speedometer. If this occurs, take the vehicle to your POLARIS dealer for 4 proper diagnosis.
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. Standard Display Distance Fuel Temperature Time Miles U.S.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays only when the Number (SPN) Number (0-9) CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine. If the CHECK ENGINE light illuminates, retrieve the error codes from the display. 1.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, 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 twenty hours of operation, or the time it takes to use the first two tanks full of fuel. No single action on your part is as important as a proper break-in period.
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.
OPERATION Starting the Engine 1. 2. 3. 4. 5. Always start the engine outdoors or in a well-ventilated area. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. Apply the brakes. Engage the park brake. Shift the transmission to neutral. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts. 6.
OPERATION Driving Procedure 1. Wear a helmet and eye protection. 2. Perform the pre-ride inspection. See page 30. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets while riding in this vehicle. 5. Start the engine and allow it to warm up. 6. Apply the service brakes and shift the transmission into gear. 7. Check your surroundings and determine your path of travel. 8. Release the park brake. 9.
OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (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.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. 2. 3. 4. Always travel straight uphill. Avoid steep hills (15 maximum). Keep both feet on the floor. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slippery or loose surfaces. 6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 7. Never go over the crest of a hill at high speed.
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 60, and take the vehicle to your dealer at the first opportunity.
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. Avoid turning at sharp angles. 6. Never open the throttle suddenly. Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2.
OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 37. Towing a trailer increases braking distance. 3. Do not tow more than the recommended weight for the vehicle.
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. Place the transmission in gear. Engage the park brake. 3. Dismount the vehicle. 4. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 5. Release the tailgate by pulling up on the tailgate latch.
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 25. 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.
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. Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive.
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 arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c.
MAINTENANCE 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. Record maintenance and service in the Maintenance Log beginning on page 95.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Hours Calendar Miles (Km) Steering - Pre-Ride - Front suspension - Pre-Ride - Rear suspension - Pre-Ride - - Pre-Ride - - Pre-Ride - Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Tires Brake fluid level Remarks (whichever comes first) Make adjustments as need ed. See Pre-Ride Checklist on page 30.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Throttle cable/throttle pedal 50 H 6M - Inspect; adjust; lubricate; replace if necessary E Throttle body air intake ducts/ flange 50 H 6M - Inspect duct for proper sealing/air leaks E Drive belt 50 H 6M - Inspect; adjust; replace as needed Cooling system (if applicable) 50 H 6M - Inspect coolant strength seasonally; pressure test system yearly Park brake cab
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 43, 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 Engine Oil PS-4 PLUS 2W-50 Brake Fluid DOT 4 Maintain level between fill lines. See page 63. Main Gearcase Oil (Transmission) AGL PLUS Transmission Fluid See page 51 (6X6).
MAINTENANCE Engine Intake Restrictor Plate Some RANGER 800 models are equipped with an intake restrictor plate in order to meet vehicle class regulations. This plate MUST NOT be removed for any reason. Removal of the intake restrictor plate will void the warranty on the vehicle. Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing 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 43. 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. Place a drain pan beneath engine crankcase. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 5.
MAINTENANCE Gearcases Gearcase Specification Chart RANGER 4X4 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug(s) Torque Drain Plug Torque Main Gearcase (Transmission) AGL PLUS Transmission Fluid 34 oz. (1000 ml) 12 ft. lbs. (16.3 Nm) 12 ft. lbs. (16.3 Nm) Front Gearcase Demand Drive Plus Fluid 9.3 oz. (275 ml) 8-10 ft. lbs. (11-13.6 Nm 11 ft. lbs.
MAINTENANCE Gearcases Transmission (Main Gearcase) (4X4/CREW) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 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.
MAINTENANCE Gearcases Transmission (Main Gearcase) (6X6) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 for the part numbers of POLARIS products. Oil Check The fill plug is located at the rear of the vehicle. 1.
MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase. 1.
MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 for the part numbers of POLARIS products. The middle gearcase fill plug is located on the side of the gearcase. Oil Check 1.
MAINTENANCE Gearcases Rear Gearcase (6X6) Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 for the part numbers of POLARIS products. The rear gearcase fill plug is on the driver's side of the rear gearcase. Oil Check Maintain the oil level even with the bottom thread of the fill plug hole. 1.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 78 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 Electrode Gap New Plug Torque Used Plug Torque All .035" (.9 mm) 18 ft. lbs. (24 Nm) 18 ft. lbs.
MAINTENANCE Cooling System 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 Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The overflow bottle is located in front of the right front wheel. 1. Position the vehicle on a level surface. 2. View the coolant level in the overflow bottle. 3.
MAINTENANCE POLARIS Variable Transmission (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 POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death. 1. Remove the seat and the underseat storage box. 2. Remove the clutch cover screws and open the clutch cover. Remove all debris wrapped in and around the PVT system. 3.
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. 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. Filter replacement is required if water is present. 3.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000 F. Allow components to cool sufficiently before proceeding. • Remove any combustible materials from the area. • Wear eye protection and gloves. • Do not stand behind or in front of the vehicle while purging.
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. 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 Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 19. 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. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause “BRAKE” to display in the rider information center, along with activation of the limiting feature. If this occurs, move the park brake lever to the forward-most position, then inspect and adjust park brake cable tension.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. Apply the brakes. Engage the park brake. Stop the engine. Place the transmission in gear. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. 2. 3. 4. Apply the brakes. Place the transmission in gear. Engage the park brake. Place the wheel in the correct position on the wheel hub.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Open the hood.
MAINTENANCE Lights Headlight Beam Adjustment X X 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 gear. Engage the park brake. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 4. Apply the brakes. Start the engine. Turn on the headlights. 5. Observe the headlight aim.
MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer. Tip: The 120 ohm resistor (if equipped) is used by your POLARIS dealer for power steering diagnostics.
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. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
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. Open the hood. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (-) battery cable first. 4. Disconnect the red (+) battery cable last. 5.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 73 before installing the battery. 1. Ensure that the battery is fully charged. Vent 2. Place the fully charged battery in the battery holder. Tube Make sure the positive terminal is toward the driver’s side of the vehicle. 3.
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 71. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 72. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: 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 any necessary repairs and clean the vehicle as recommended. See page 74. 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.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 43. Battery Maintenance See page 72 for storage and charging procedures. Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 43.
MAINTENANCE 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 30. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5.
SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity 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 Dimensions (Inside) Ground Clearance Min.
SPECIFICATIONS RANGER 4X4 Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Rear Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R) 7.70:1 7.00:1 3.6:1 3.818:1 3.
SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity 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 Cargo Box Dimensions (Inside) Ground Clearance Min.
SPECIFICATIONS RANGER 6X6 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, Park Hood Headlight Taillights Brake Light PVT Single Lever, Console (H/L/N/R) 8.71:1 7.91:1 3.85:1 3.818:1 3.
SPECIFICATIONS RANGER CREW Maximum Weight Capacity 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 Dimensions (Inside) Ground Clearance Min.
SPECIFICATIONS RANGER CREW 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 PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R) 7.70:1 7.0:1 4.63:1 3.818:1 3.
POLARIS PRODUCTS Part Number Description 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) 2878068 AGL PLUS Transmission Fluid (qt./.95 l) Engine Lubricant Gearcase / Transmission Lubricants 2878069 AGL PLUS Transmission Fluid (gal./3.8 l) 2877922 Demand Drive Plus Fluid (qt./.95 l) 2877923 Demand Drive Plus Fluid (gal./3.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 34. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes.
TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Park brake is not completely disengaged Park brake connector malfunction or switch movement or failure Solution Ensure lever is in forward-most position Disconnect the connector if temporary continued operation is necessary, see your dealer promptly for service Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution
TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plug Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure Loose ignition connections Water present in fuel Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with fresh recommended fuel See your dealer See your dealer See your dealer Check all connections and tighten Replace with fresh recommended fu
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Low octane fuel Possible Rich Fuel Cause Fuel is very high octane 88 Solution Inspect, clean and/or replace spark plugs See your dealer Set gap to sp
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine Solution Refuel Replace with new fuel Inspect, clean and/or replace spark plug See your dealer Set gap to specs or replace plug Check all connections and tighten Recharge the battery to
WARRANTY LIMITED 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. POLARIS also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects. 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.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY SPARK ARRESTER POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard 5100-1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations. Exported Vehicles 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.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty This limited warranty excludes failures not caused by a defect in material or workmanship.This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing competition.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
INDEX A C Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . 17 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Air Filter Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 60 All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 40-41 Disengaging AWD . . . . . . . . . . . . . . . 40 Engaging AWD. . . . . . . . . . . . . . . . . . 40 Locking the Differential . . . . . . . . . . . 41 All Wheel Drive Switch. . . . . . . . . . . . . . . . . . . .
INDEX E G Engine Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 31 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Equipment Modifications . . . . . . . . . . . . . . . . . . . 12 Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 28 Exhaust Emission Control System . . . . . . . . . . . . 42 Exhaust System Warning . . . . . . . . . . . . . . . . . . . 61 Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gap, Spark Plug .
INDEX N P Noise Emission Control System . . . . . . . . . . . . . 42 Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Steering Unit (Cleaning) . . . . . . . . . . . . . . 66 Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . 30 Product Part Numbers . . . . . . . . . . . . . . . . . . . . . . 84 Public Lands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 PVT Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PVT Drying . . . . .
INDEX S T Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Spring, Shock, Adjustment . . . . . . . . . . . . . . . . . . 64 Stabilizing the Fuel . . . . . . . . . . . . . . . . . . . . . . . . 75 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . 31 Steering Wheel Inspection . . . . . . . . . . . . . . . . . . 64 Steering Wheel, Adjustment . . . . . . . . . . . . . . . . . 19 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . 31 Storage . . . . . . .
