PMS 419 2019 RANGER EV Owner's Manual for Maintenance and Safety
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2019 Owner’s Manual RANGER® EV
POLARIS®, RANGER®, and POLARIS GENERAL™ are trademarks of POLARIS Industries Inc. Copyright 2018 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.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
WELCOME 4
Introduction . . . . . Safety . . . . . . . . Features and Controls Operation . . . . . . Winch Guide. . . . . Maintenance . . . . Specifications . . . . POLARIS Products . . Troubleshooting . . . Warranty . . . . . . Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in serious injury.
INTRODUCTION DECLARATION OF CONFORMITY Polaris Sales Europe Sàrl Place de l’Industrie 2 1180 Rolle, Switzerland Telephone +41213–218–700 DECLARATION OF CONFORMITY October 1, 2018 Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements to all terrain vehicles.
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 SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, overthe-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.
SAFETY 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 PASSENGER / TIRE PRESSURE WARNING WARNING • • • • Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Read the Owner’s Manual. Never carry fuel on this vehicle. WARNING 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 BATTERY CHARGING WARNING (7185977) WARNING • Explosive gases are released when batteries are charged. Keep sparks, flames and cigarettes away. Shield eyes when working near batteries. • Do not charge batteries in a non-ventilated enclosed area or near flammable materials. • Do not attempt to charge frozen, leaking, or damaged batteries. • Connect battery charger to properly rated electrical receptacle with GFCI.
SAFETY SAFETY LABEL LOCATIONS q General Alert w Battery Charging Warning e Pass.
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 • Always follow proper procedures for climbing hills as described in this manual. See page 37. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. 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. See page 37. Check the terrain carefully before descending a hill. Never travel downhill at high speed.
SAFETY EQUIPMENT MODIFICATIONS Never install any accessory that grounds to the vehicle chassis. The chassis is a floating ground to protect against electrical short circuits and hazards. Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.
SAFETY 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. Never operate with a passenger under the age of 12. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold (if equipped).
SAFETY SEAT BELTS Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. All riders must wear seat belts at all times. PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.
SAFETY CARRYING A PASSENGER A passenger must always be seated in a passenger seat with seat belt secured. Carrying more than one passenger in a 2-seat vehicle can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover. Never carry more than one passenger in a 2-seat vehicle. VENTILATION WHEN CHARGING BATTERIES Failure to provide adequate ventilation while charging batteries can result in an explosion.
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. The vehicle’s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle.
SAFETY OPERATING A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems. OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control.
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).
SAFETY IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice.
SAFETY PRECAUTIONS DURING MAINTENANCE WARNING Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries. Always disconnect the main power connector before servicing or unplugging any electrical components. Always follow all safety instructions in the maintenance portion of this owner’s manual, as well as the following: • Make sure the vehicle is properly immobilized before beginning any maintenance.
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FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS q ROPS Frame w Hip Bars e Seat Belt r Cargo Box t Headlight y Front Bumper/Brush Guard u Cargo Box Release Lever i Tailgate Latches o Taillights a Receiver Hitch 29
FEATURES AND CONTROLS CONSOLE q Indicator Lights w Hour Meter e Battery Discharge Indicator r Direction Selector t AWD Switch 30 y Drive Mode Switch u 12V Auxiliary Outlet i Charge Status Indicator o Headlight Switch a Key Switch
FEATURES AND CONTROLS INDICATOR PANEL LIGHTS The indicator lights activate when the key is in the ON position.
FEATURES AND CONTROLS BATTERY DISCHARGE INDICATOR The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the gauge will display 100%. The charge status indicator will be solid green. NOTE Avoid discharging the batteries below 20% on the discharge indicator. HOUR METER The hour meter records and displays the hours of actual vehicle movement since manufacture.
FEATURES AND CONTROLS SWITCHES KEY SWITCH Turn the key to the ON position to activate the electrical circuits. Turn the key to the OFF position to disable all electrical circuits. The key can be removed from the switch when it is in the OFF position. HEADLIGHT SWITCH Press the top of the switch to turn the headlights on. Press the bottom of the switch to turn the headlights off. DIRECTION SELECTOR SWITCH When the direction selector is in the center position, the vehicle is in neutral.
FEATURES AND CONTROLS AWD SWITCH The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode). Press the top of the switch to engage All Wheel Drive (AWD). Move the switch to the center position to lock the differential and operate in two wheel drive (2WD). Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD).
FEATURES AND CONTROLS DRIVE MODE SWITCH CAUTION Changing the drive mode switch position while driving could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure. Press the top of the switch to select high mode. Use high mode for most trail-riding conditions. The vehicle will operate at speeds up to 25 MPH (40 km/h). Press the bottom of the switch to select low mode. Low mode is recommended for short-term operation in extreme load conditions.
FEATURES AND CONTROLS BATTERIES This vehicle is equipped with eight 12-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual. BATTERY HANDLING PRECAUTIONS • Always make sure that all electrical accessories are grounded directly to the negative (-) post on the terminal board.
FEATURES AND CONTROLS AMBIENT TEMPERATURE IMPLICATIONS ON BATTERIES • Battery range decreases as ambient temperature decreases. This can affect the range by up to 30%. • Batteries discharge when left uncharged. They can discharge up to 13% per month (higher rates in warmer climates) with the key off and much faster if the key is left on. • Batteries can freeze if left uncharged at low ambient temperatures. Percent Charged 100% 50% 0% Approx.
FEATURES AND CONTROLS MAIN POWER CONNECTOR NOTE Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components. When disconnected, the main power connector disconnects the battery pack from all electrical components, with the exception of the contactor.
FEATURES AND CONTROLS PARK BRAKE LEVER (IF EQUIPPED) Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.
FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal q to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.
FEATURES AND CONTROLS SEATS 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 BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle.
FEATURES AND CONTROLS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured. The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.
FEATURES AND CONTROLS MALFUNCTION INDICATOR TROUBLESHOOTING GUIDE The malfunction codes will blink on the controller. The code definitions provided here are for informational purposes only. TIP If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault (reversing direction without releasing the accelerator), select neutral and turn the key off and on to clear the error. If the error does not clear, please see your dealer for diagnosis and repair.
FEATURES AND CONTROLS CHARGE STATUS INDICATOR TROUBLESHOOTING GUIDE The code definitions provided are for informational purposes only. Please see your dealer for diagnosis and repair.
FEATURES AND CONTROLS CHARGING CORD The charging cord is located under the hood on the right side of the vehicle. See page 62 for charging instructions. AUXILIARY OUTLET The 12-volt receptacle can be used to power accessories, but is limited to 10 amps (the terminal board and 12-volt outlet are fused together at 10 amps. AUXILIARY 12-VOLT TERMINAL BOARD The 12-volt terminal board is located under the hood.
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OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
OPERATION ITEM REMARKS REF.
OPERATION DRIVING PROCEDURE 1. Disconnect the charging cable (if connected). 2. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 3. Sit in the driver's seat and fasten the seat belt. 4. Apply the brakes. 5. Turn the key to the ON position. Wait about a second for the contactor to close before continuing. 6. Move the direction selector to forward or reverse. 7. Move the drive mode switch to the desired setting. 8. Release the park brake. 9.
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. When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding.
OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5. Proceed at a steady rate of speed. 6. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 7.
OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4.
OPERATION 6. Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover. 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.
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 The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Move the drive mode switch to low mode if needed. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle. Never exceed the following capacities. MODEL RANGER EV MAXIMUM CAPACITIES (LEVEL GROUND) CARGO BOX 454 kg (1000 lbs.) 226 kg 500 lbs.
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 68.1 kg (150 lbs.) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 16 km/h (10 MPH) when towing. Towing a trailer increases braking distance. 3. Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the Specifications section. 4.
OPERATION TOWING THE VEHICLE NOTICE When towing the vehicle, the key MUST be in the OFF position or severe motor damage will occur. Follow these procedures when towing the vehicle: 1. Turn the key off. 2. Always follow these precautions when towing this vehicle: • • • • • • Do not operate faster than 10 MPH (16 km/h). Do not tow on public streets. Do not allow passengers in the towed vehicle. Avoid abrupt starts and stops. Avoid sharp turns and abrupt steering maneuvers. Avoid towing on a hill.
OPERATION DUMPING THE CARGO BOX WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box. 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3.
OPERATION TRANSPORTING THE VEHICLE When transporting the RANGER for a long distance or on public streets, always use a trailer with an approved load rating greater than the RANGER’s curb vehicle weight of 771 kg (1700 lbs.) plus any installed accessories or cargo. Follow these guidelines when transporting the RANGER. 1. Set the park brake. 2. Remove the key to prevent loss. 3. Secure the seat, hood and tailgate latches. Ensure that the seats are attached correctly and are not loose. 4.
OPERATION ALL WHEEL DRIVE (AWD) Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off. The AWD switch may be turned on or off while the vehicle is moving. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.
OPERATION 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.
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WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 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.
WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 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.
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 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • 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” 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. This can result in SEVERE INJURY or DEATH.
WINCH GUIDE WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation. 9.
WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15.
WINCH GUIDE 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition. A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged.
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.
MAINTENANCE 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 dealer. Record maintenance and service in the Maintenance Log.
MAINTENANCE MAINTENANCE CHART KEY SYMBOL XU DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized Polaris dealer or other qualified person perform these services. D WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM XU D General lubrication HOURS CALENDAR KM (MILES) 50 H 3M – Lubricate all fittings, pivots, cables, etc.
MAINTENANCE GEARCASES GEARCASE SPECIFICATION CHART GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG TORQUE Main Gearcase (Transaxle) ATV Angle Drive Fluid 20.3 oz. (600 ml) 14 ft lbs. (19.4 Nm) 14 ft lbs (19.4 Nm) Front Gearcase Demand Drive Fluid 5.1 oz. (150 ml) 8–10 ft lbs. (11–13.6 Nm) 11 ft lbs. (15 Nm) MAIN GEARCASE (TRANSAXLE) Always check and change the main gearcase oil at the intervals outlined in the Periodic Maintenance Chart.
MAINTENANCE OIL CHANGE The drain plug w is located on the lower right side of the main gearcase, near the fill plug q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. To change the oil, do the following: 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely. 3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings. 4. Reinstall the drain plug.
MAINTENANCE FRONT GEARCASE Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. OIL CHECK The front gearcase fill plug is located on the left side of the front gearcase. To check the oil, do the following: 1. Position the vehicle on a level surface. 2.
MAINTENANCE OIL CHANGE The drain plug w is located on the lower right side of the main gearcase, near the fill plug q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. To change the oil, do the following: 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's side. 3. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely. 4.
MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. Proceed to the next page for brake fluid information.
MAINTENANCE To check the brake fluid level, do the following: 1. Position the vehicle on a level surface. 2. View the brake fluid level at the reservoir in the driver’s side wheel well. The level should be between the upper (MAX) q and lower (MIN) w level lines. 3. If the fluid level is lower than the upper level line, add brake fluid to the upper (MAX) line q. 4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.
MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. To inspect the brakes, do the following: 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.
MAINTENANCE SUSPENSION ADJUSTMENT Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension. Always heed the following rules if you make adjustments to this suspension. • Always return the suspension to the lowest (softest) setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.
MAINTENANCE TIRES WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8” (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
MAINTENANCE WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. WHEEL INSTALLATION 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
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 5. Reinstall the harness assembly into the headlight assembly. HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. Turn on the headlights. 4. Observe the headlight aim.
MAINTENANCE BRAKE LIGHTS When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. To check the brake lights, do the following: 1. Turn the key to the ON position. 2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb. INDICATOR LAMP REPLACEMENT To replace the indicator lamp, do the following: 1. Lift the hood. 2.
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 Always follow these precautions when charging the batteries: 1. Position the vehicle on a level surface. 2. Make sure the charging area is well ventilated. 3. Make sure the key is off. 4. Open the hood and any door enclosures or zippers. 5. Always use a extension cord with a minimum rating of 20 amps. 6. Inspect the charging cord and extension cord for cracks, loose connections and frayed wiring. Replace any damaged components promptly. 7.
MAINTENANCE BATTERY INSPECTIONS Inspect battery terminal connections monthly. Clean batteries as recommended. Using an insulated wrench, torque bolts to 8 ft. lbs. (11 Nm). BATTERY CLEANING Always keep battery terminals and connections free of corrosion. To clean, remove 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 battery terminals with dielectric grease or petroleum jelly.
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. NOTE High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTE Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE WASHING TIPS • • • • Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. 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. • Grease all zerk fittings immediately after washing.
MAINTENANCE CHROME WHEEL CARE (IF EQUIPPED) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted surfaces.
MAINTENANCE STORING THE VEHICLE Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. 2. Clean the batteries. 3. Store the vehicle out of the sun in a cool, dry place. 4. Be sure the storage area is well ventilated. 5. Turn the key off. 6. DO NOT set the park brake. 7. Verify that tire pressure is at specification. 8. Block the wheels to prevent rolling. 9. Fully charge the batteries.
MAINTENANCE 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. FLUID LEVELS Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.
MAINTENANCE TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle. 1. Apply the brakes. 2. Place the transmission in PARK. Stop the engine. 3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. Engage the park brake. 4. Remove the key to prevent loss during transporting. 5. Secure the fuel cap (if equipped) and seat. Ensure that the seat is attached correctly and is not loose.
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SPECIFICATIONS SPECIFICATIONS DIMENSIONS Dry Weight 1750 lbs. (793.8 kg) Test GVW - Rollover Protection System (ROPS) 2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53 Ground Clearance 10 in. (25.4 cm) Length 108 in. (274.3 cm) Width 56.5 in. (143.5 cm) Height 73 in. (185.4 cm) Wheelbase 72 in. (183 cm) Turning Radius 150 in. (381 cm) LOAD CAPACITY Box Dimensions (Inside) 32 x 42 x 11.5 in. (81 x 107 x 29 cm) Box Capacity 500 lbs. (227 kg) Payload Capacity 1000 lbs.
SPECIFICATIONS PERFORMANCE Maximum speed 25 MPH (40.2 km/h) Range (in Max Range mode on flat ground) 50 miles (80.
SPECIFICATIONS FEATURES Charge indicator Digital, indicates battery discharge Hour meter Digital, indicates cumulative hours of vehicle movement Auxiliary power 12-volt accessory outlet Rider restraints Automotive-style 3-point seat belts Multi-mode switch L/M/H (Low/Max Range/High) Headlights/taillights/brake lights Dual 50-watt Storage Glove box NOISE AT OPERATOR’S EAR A-Weighted Sound Pressure at Rider’s Ear 69 dB(A) C-Weighted Sound Pressure Level 76 dB(C) A-Weighted Sound Power Level
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POLARIS PRODUCTS POLARIS PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil (355 ml/12 oz. Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (.95 l/1 qt.) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (3.8 l/1 gal.) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (.95 l/1 qt.) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (3.8 l/1 gal.) 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (.95 l/1 qt.
POLARIS PRODUCTS PART NUMBER 104 DESCRIPTION 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger
TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving at low RPM or ground speed 5–11 km/h (3-7 MPH) Drive at a higher speed. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow/easy clutch engagement Use the throttle quickly and effectively.
TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.
TROUBLESHOOTING ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect, clean and/or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or nonrecommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires Your dealer can assist Mechanical failure Your dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel ENGINE PINGS
TROUBLESHOOTING ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to
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WARRANTY WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a ONE YEAR LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester 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 This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY 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 EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
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MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.
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A Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 40 Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 20 All Wheel Drive (AWD). . . . . . . . . . . . . . . . 60 Auxiliary 12-Volt Terminal Board . . . 45 Axle and Wheel Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 84 B Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Headlight Beam Adjustment. . . . . . . . . 87 Headlight Lamp Replacement . . . . . . 86 Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 33 Hot Drive Systems . . . . . . . . . . . . . . . . . . . . . 26 Hour Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 How To Obtain Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 I Oil Change. . . . . . . . . . . . . . . . .
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Severe Use Definition . . . . . . . . . . . . . . . . . 73 Shock Loading the Winch . . . . . . . . . . . . 71 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Stalling While Climbing a Hill . . . . . . . . 25 Steering Wheel Inspection . . . . . . . . . . . 82 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PMS 419 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Place de l'Industrie 2 Rolle, Switzerland Part No.
