2017 RANGER® 1000 Diesel RANGER® 1000 Diesel EPS RANGER CREW® 1000 Diesel 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. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
POLARIS®, RANGER® and RANGER CREW® are trademarks of POLARIS Industries Inc. Copyright 2016 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.
INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
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.
INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces 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.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements.
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 Fuel Transport Warning This label can be found in the rear cargo box. WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. 7185278 Payload Warning/Shift Caution WARNING Diesel Never exceed 20 MPH (32.2 Km/h) if total payload is greater than 1080 lbs. (490 kg). CREW Diesel Never exceed 35 MPH (56.3 Km/h) if total payload is greater than 1490 lbs. (676 Kg).
SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. • If total payload is greater than 500 lbs., the vehicle must be operated in LOW range. X 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 Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain. • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
SAFETY Operator Safety • Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. • Never modify this vehicle through improper installation or use of non-POLARIS approved accessories. • 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.
SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license.
SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
SAFETY Operator Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle.
SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds. Jumps and Stunts Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover. Never attempt wheelies, jumps, or other stunts.
SAFETY Operator Safety Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly).
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab nets (or doors). Not all models come with all features. Refer to the specifications section on page 100.
FEATURES AND CONTROLS Console Instrument Cluster Cup Holder Gear Selector (Shifter) Storage Tray 12V Auxiliary Outlets Storage Compartment Auxiliary Outlets The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the dash. Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER.
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 After the glow plug indicator light turns off, turn the key to the START position to engage the starter. The key returns to the ON position when released.
FEATURES AND CONTROLS Switches ADC Switch (if applicable) The ADC switch has two positions (ON/OFF). ADC will activate when all of the following conditions are met: • AWD mode is engaged. • No throttle applied. • Vehicle speed is between 1-12.5 MPH. • ADC switch is in ON position. ADC Switch 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.
FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery. Pull the rear edge of a seat upward to release the latch pins from the grommets. Roll the seat forward to access the under-seat area.
FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver’s seat. Use only the recommended diesel fuel. See page 37. Hood Latches Remove the hood to access the coolant overflow bottle, the radiator cap and the headlight adjustment screws. To remove the hood, rotate the hood latches 1/4-turn and lift the hood away from the vehicle.
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 Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) 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 and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating. 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. To wear the seat belt properly, follow this procedure: 1.
FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. NOTICE: High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the instrument cluster lens and other plastic surfaces.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center 3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode. 4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the high beam position. 5. Fuel Level Indicator - LCD bar graph indicating current fuel level. All segments will flash when the last segment is cleared indicating a low fuel warning. 6.
FEATURES AND CONTROLS Instrument Cluster Information Display Area The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock.
FEATURES AND CONTROLS Instrument Cluster Information Display Area Tachometer (RPM) Engine RPM can be displayed digitally. Engine Temperature Engine temperature can be displayed in °F or °C. Refer to “Units of Measurement” to change the format. Clock The clock displays the time in a 12-hour or 24-hour format. Refer to “Units of Measurement” to change the format (Standard 12-hour / Metric 24-hour). To set the clock, follow these steps: 1. Toggle the MODE button until the odometer is displayed. 2.
FEATURES AND CONTROLS Instrument Cluster Information Display Area Programmable Service Interval The initial factory service interval setting is 50 hours. Each time the engine is started, the engine hours are subtracted from the service interval hours. When the service interval reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started. To change the hour setting or reset the function, follow these steps: 1.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER is the first 50 hours of operation. 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 Fuel Recommendations NOTICE: For the best engine performance, to prevent engine damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel fuel. POLARIS recommends the following diesel fuels for use in this vehicle: • Ultra Low Sulfur #2 • #1 Diesel Fuel containing no more than 20% bio-diesel (see page 38) See page 40 for cold weather fuel blend recommendations.
OPERATION Fuel Recommendations Bio-Diesel Fuels In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. KOHLER approves the use of bio-diesel fuels that do not exceed a blend of 20% (by volume) of FAME with 80% (by volume) of approved mineral oil derived diesel fuel.
OPERATION Fuel Recommendations Bio-Diesel Fuels B21 To B100 Bio-diesel Fuel Blend Usage B21 to B100 bio-diesel is not approved for this POLARIS application. Approved Engines Only the KOHLER KDW engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applications. NOTICE: Do not exceed bio-diesel fuel blend B20 for this POLARIS application.
OPERATION Fuel Recommendations Refueling The fuel tank filler cap is located on the right side of the vehicle near the passenger seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill. Cold Weather Operation Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the following fuel blending guideline to prevent this from occurring. Fuel Blending Guideline Temperature No. 2 No.
OPERATION Cold Weather Operation Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle. See page 38. Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle: • Cold weather conditions can lead to plugged fuel system components and hard starting. • Bio-diesel blended fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components.
OPERATION Operating Conditions NOTICE: Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear. • Avoid operating in the presence of chemical gases or fumes. • Avoid operating in a corrosive atmosphere such as salt water spray. • NEVER operate the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood. • NEVER expose the engine to the rain.
OPERATION Starting the Engine NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Before operating this vehicle in cold weather, review the cold weather operation information beginning on page 40. Always wait for the glow plug indicator light to turn off before cranking the engine. START HELP 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors). 3. Place the transmission in PARK.
OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection. See page 36. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets (or doors) while riding in this vehicle. 5. Place the transmission in PARK. 6. Start the engine and allow it to warm up. 7. Apply the service brakes and shift the transmission into gear. 8. Check your surroundings and determine your path of travel. 9.
OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 36. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. Make sure all passengers are wearing an approved helmet, eye protection, gloves, longsleeve shirt, long pants and over-the-ankle boots. 4. Make sure all passengers secure their seat belt. 5.
OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. 2. 3. 4. Always travel straight uphill. Avoid excessively steep hills. Keep both feet on the floor. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5. Proceed at a steady rate of speed and throttle pedal position. Never apply throttle suddenly. 6. 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: If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 80, and take the vehicle in for service 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. Apply only light throttle. Never apply throttle suddenly.
OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3. Place the transmission in PARK. 4. Turn the engine off. 5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 6.
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. When transporting heavy loads and/or when towing, always operate the vehicle in low gear and have ADC activated (if equipped). 3. When towing a disabled RANGER vehicle, place the disabled vehicle’s transmission in neutral.
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 PARK. 3. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 4. 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 31. 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.
WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. Winch Safety Precautions 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 16.
WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to think through the winching you are about to do. • Proceed slowly and deliberately.
WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” NO YES is designed to stretch. WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks.
WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. B. C. D. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15. After winching is complete, especially if winching at an angle, it may be necessary to redistribute the winch cable across the winch drum. You will need an assistant to perform this task. A. B. C. D. E. F. Release the clutch on the winch.
WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders. Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to “jerk” a load with the winch.
WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3.
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 Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering Front suspension Rear suspension Tires Pre-Ride Brake fluid level Make adjustments as needed. See Pre-Ride Checklist on page 36.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar D Throttle pedal Throttle body air intake ducts/ flange Remarks (whichever comes first) Miles (Km) 50 H 6M 500 (800) Inspect for free movement; replace pedal as needed 50 H 6M 500 (800) Inspect duct for proper sealing/air leaks Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as needed Cooling system (if applicable) 50 H 6M 500 (800) Inspect coolant strength seasonally; pressure test system yearly Ź
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65, 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.
MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components. Access the oil fill cap, dipstick and filter under the Oil Fill cargo box. Cap 1. Remove all cargo from the cargo box. See page 53. 2. Position the vehicle on a level surface. 3. Place the transmission in PARK. 4. Stop the engine. 5.
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 65. Always change the oil filter whenever changing oil. The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole in the skid plate under the crankcase (see next page). CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components.
MAINTENANCE Engine Oil Oil and Filter Change 12. Reinstall the drain plug. Torque the drain plug to 29.5 ft. lbs. (40 Nm). 13. Remove the oil fill cap and add 3 quarts (2.8 l) of recommended oil. Reinstall the fill cap. 14. Start the engine and check for leaks. 15. Stop the engine and wait 15 seconds before removing the dipstick. 16. Remove the dipstick. Wipe it dry with a clean cloth. 17. Reinstall the dipstick completely. Remove the dipstick and check the oil level. 18.
MAINTENANCE Gearcases Gearcase Specification Chart RANGER Diesel/RANGER CREW Diesel Gearcase Specifications Gearcase Lubricant Capacity Main Gearcase (Transmission) AGL Gearcase Lubricant & Transmission Fluid 40.6 oz. (1200 ml) Fill Plug Torque Drain Plug Torque 12 ft. lbs. (16.3 Nm) 12 ft. lbs. (16.3 Nm) Front Gearcase Demand Drive Fluid 6.76-7.6 oz. (200-225 ml) 8-10 ft. lbs. (11-13.6 Nm) 8-10 ft. lbs. (11-13.
MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 104 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 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 65. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level Maximum surface. LY ON Level NT A L O 2. Place the transmission in PARK. CO (Cold) 3. Remove the hood. See page 26. 4. View the coolant level in the Minimum overflow bottle. Level 5.
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, loss of control and severe injury or death. 1. Position the vehicle on a level surface. Block the wheels to prevent vehicle movement. Place the transmission in neutral. 2. Lift the cargo box. 3.
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 8. Rotate the driven clutch by hand until the belt is completely off. Step 8 9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it. 10. Remove all debris wrapped in and around the PVT system. 11. Remove all debris from the entire clutch air duct passage. 12. Check for signs of damage to seals on the transmission and engine.
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 14. Reinstall the clutch cover in the reverse order of removal, fitting the top of the cover into place, then working the bottom of the cover over the suspension. 15. Install all clutch cover screws. Torque to 4-5 ft. lbs. (5.5-6.5 Nm). Step 13 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.
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your RANGER in for service before starting it, follow the steps outlined below. 1. Move the vehicle to dry land or at the very least, to water below the floorboard. 2. Inspect the air box for water.
MAINTENANCE Filter Systems Air Filter Always change the air filter at the 5 Latches intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the air filter more Air frequently if the vehicle is operated Filter in wet or dusty conditions or at high throttle for extended periods. 1. Lift the cargo box to access the air box. Right Side Left Side View View 2. Release the five (5) air box cover latches and lower the bottom to expose the air filter. 3. Remove the air filter. 4.
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 Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 65. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle. See page 43. 1. Raise the cargo box. 2. The belt tension is correct with Mid Span Adjustment Bolt 5/16-1/2 in. (7-10 mm) of belt deflection at the mid span of the belt, when 20 lbf (89 N) is applied to the belt. 3.
MAINTENANCE Fuel Filter/Water Separator The fuel filter/water separator is located under the seat on the right side of the vehicle, between the engine and fuel tank. Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the separator more frequently if the vehicle is operated with inferior fuel. CAUTION! Both fuel and water will drain from the separator during the following procedure.
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 take your vehicle in for service if throttle problems arise.
MAINTENANCE Brakes WARNING Do not perform maintenance immediately after the vehicle has been operated, as the brake system may become very hot. Serious burns could result from contact with hot brake components. Allow components to cool before proceeding. • Wear eye protection and gloves. 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.
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol. WARNING! Do not apply WD-40 or any petroleum product to brake discs.
MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting positions. 2. Reposition the shocks to the outside mounting holes. 3. Reinstall the shock mounting bolts. Torque to 40 ft. lbs. (54.2 Nm).
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 POLARIS-approved size and type of tires for this vehicle when replacing tires.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine. 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. Place the transmission in PARK. 2. 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. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers.
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 PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 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. Raise the passenger seat to access the fuses. Spare fuses are provided in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box.
MAINTENANCE Battery Your vehicle has a sealed battery, which requires little maintenance. Always keep 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.
MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged.
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 Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.
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 65. Battery Maintenance See page 94 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 65.
MAINTENANCE Removal from Storage 1. Charge the battery if necessary. Install it in the vehicle. 2. Fill the fuel tank with fuel. 3. Check all the points listed in the Daily Pre-Ride Inspection section on page 36. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 4. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Transporting the RANGER Follow these procedures when transporting the vehicle. 1.
SPECIFICATIONS RANGER Diesel Maximum Weight Capacity Dry Weight Test GVW - Rollover Protection System (ROPS) 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 Diesel Driving System Type Shift Type Transmission Gear Ratio - High Transmission Gear Ratio - Low Transmission Gear Ratio - Reverse Front Drive Ratio Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlight Taillights Brake Light PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R/P) Front 3.10:1 / Rear 9.26:1 Front 7.62:1 / Rear 22.79:1 Front 6.83:1 / Rear 20.41:1 3.
SPECIFICATIONS RANGER CREW Diesel Maximum Weight Capacity Dry Weight Test GVW - Rollover Protection System (ROPS) 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 Diesel Driving System Type Shift Type Transmission Gear Ratio - High Transmission Gear Ratio - Low Transmission Gear Ratio - Reverse Front Drive Ratio Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlight Taillights Brake Light PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R/P) Front 3.10:1 / Rear 9.26:1 Front 7.62:1 / Rear 22.79:1 Front 6.83:1 / Rear 20.41:1 3.
POLARIS PRODUCTS Part Number Description Engine Lubricant 2878473 15W-40 Diesel Oil (2 qt./1.9 l) 2879832 5W-40 Synthetic Diesel Oil (2 qt./1.9 l) Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l) 2877922 Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (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 47. 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 Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose starter connections Loose electronic control box connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Poor fuel quality or incorrect fuel Low fuel level Clogged fuel filter Clogged air filter Loose ignition connections Water present in fuel Kinked or plugged fuel tank vent line Other mechanical failure Solution Replace with recommended fuel Refuel Replace Replace Check all connections and tighten Replace with new fuel Inspect and replace Your POLARIS dealer can assist.
WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product 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.
WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY Kohler Co. provides the California and Federal emission control warranty on this vehicle. However, you may always utilize your Polaris dealer as a first point of contact for standard warranty or emissions warranty requests. While most inquiries can be resolved by working with your Polaris dealer, any unresolved emission-related concerns can be pursued further with Kohler Co. as described in the following emission control warranty statement.
WARRANTY COVERAGE Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts. The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE 114 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A D Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 22 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 81 All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 54-55 Disengaging AWD. . . . . . . . . . . . . . . . . . . . . . 54 Engaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 54 Locking the Differential. . . . . . . . . . . . . . . . . .
INDEX F O Fuel Tank Filler Cap . . . . . . . . . . . . . . . . . . . . . . 26 Fuel, Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fuels, Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . 38-39 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Oil Change Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71 Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . 73 Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . .
INDEX S U Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Shock Loading the Winch. . . . . . . . . . . . . . . . . . . 62 Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 88 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spark Arrester Warning . . . . . . . . . . . . . . . . . . . . 82 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • If you are under age 16 and without a valid driver’s license. • Without first viewing safety video and taking a ROHVA training course at www.rohva.org. • On excessively steep hills. • On public roads (unless designated for off-road use). • With a passenger who is not seated in a passenger seat, or with passengers under age 12 or who cannot comfortably reach the floor and hand holds.
