PMS 419 2019 RANGER XP 1000 EU / Zugmaschine Owner's Manual for Maintenance and Safety
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2019 Owner’s Manual RANGER® XP 1000 EU / Zugmaschine
POLARIS® and RANGER® 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. Depictions and/or procedures in this publication are intended for reference use only.
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. . . . . . . Emission Control Systems . Maintenance . . . . . . Specifications . . . . . . POLARIS Products . . . . Troubleshooting . . . . . Warranty . . . . . . . . Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION INTRODUCTION This POLARIS vehicle is designed for off-road operation. 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.
INTRODUCTION 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. 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.
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SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com. Your POLARIS vehicle is designed for off-road operation. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
SAFETY 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. Parents should verify that the young operator has a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
SAFETY 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 GENERAL ALERT (7187455) Read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Never use alcohol or drugs before or while driving or riding. This vehicle is not approved for on-road operation. Wear approved helmet, goggles, and protective clothing. Always wear seat belts. Always use the cab nets or doors. Never exceed seating capacity. GENERAL ALERT (7188512) (ZUGMASCHINE MODELS ONLY) Read the owner’s manual.
SAFETY LOAD/PASSENGER/TIRE PRESSURE ALERT (7187424) Never carry passengers in cargo box. Passengers can be thrown off. This can cause serious injury or death. Read owner's manual. NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. RANGER XP 1000 EU/ZUG MAXIMUM CARGO BOX LOAD 454 kg (1000 lbs.
SAFETY CLUTCH COVER ALERT (7181427) Keep body parts away from belt. Read owner's manual.
SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle 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 and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures.
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 • Always place the transmission in PARK before getting out of the vehicle. • Always engage the park brake (if equipped) when leaving the vehicle unattended. • Always stop the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. • Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver’s license and proper training, or accidental starting.
SAFETY OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).
SAFETY 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. Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. DUST EXPOSURE Exposure to dust created by the movement of the vehicle in dry weather may lead to respiratory distress. Be aware of operating environments and take precautions to avoid dust ingestion.
SAFETY OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability. 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 ON PUBLIC ROADS Zugmaschine and Tractor Models This vehicle is approved for on-road operation. Other Models Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for offhighway use). OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control.
SAFETY STALLING WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed. If you begin rolling downhill: Never apply engine power.
SAFETY OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. OPERATING THROUGH WATER Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident.
SAFETY POOR VISIBILITY Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
SAFETY UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use. EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability.
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FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS q Console u CV Boot/Rear Caliper w Headlights i Receiver Hitch e Bumper/Brush Guard o ROPS Cab Frame r Radiator a Hip Bar t Tailgate s Cargo Box y Taillights d Fuel Cap 29
FEATURES AND CONTROLS CONSOLE q Steering Wheel Adjustment Lever w Instrument Cluster e Ignition r Gear Selector (Shifter) t Hazard Switch y Park Brake Lever STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
FEATURES AND CONTROLS GEAR SELECTOR To change gears, stop the vehicle, and with the engine idling, move the lever r to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. • • • • • H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK.
FEATURES AND CONTROLS SWITCHES Not all switches are present on every model. IGNITION SWITCH / LIGHT SWITCH Use the ignition switch to start the engine and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position. 32 OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off. LIGHTS ON All lights are on. Electrical circuits are on. Electrical equipment can be used. POSITION LIGHTS ON The headlights are off. Position lights are on.
FEATURES AND CONTROLS TURN SIGNAL LEVER Before turning, activate a turn signal to alert others of your intentions. Check turn signal lamps before each ride. TIP The key must be in the ON position to activate the turn signals. Move the turn signal lever downward q to signal a left turn. The left turn signal lamps in the taillight and below the front headlight will flash. The turn signal indicator in the gauge will also flash. Move the lever upward w to signal a right turn.
FEATURES AND CONTROLS POLARIS 3-MODE THROTTLE CONTROL SWITCH The Polaris 3-Mode Throttle Control Switch has three positions: • Performance (PERF) • Standard (STND) • Work (WORK) Always use low gear for any of the following conditions regardless of the selected throttle control setting. • • • • Operating in rough terrain or over obstacles. Loading the vehicle onto a trailer. Towing heavy loads. Driving frequently at low RPM or at ground speeds below 11 km/h (7 MPH).
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. THROTTLE PEDAL Push the throttle pedal w down to increase engine speed.
FEATURES AND CONTROLS PARK BRAKE LEVER 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 SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers. 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. WARNING Falling from a moving vehicle could result in serious injury or death.
FEATURES AND CONTROLS 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. A click indicates that it's securely latched. 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness.
FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. Turn the key off and on to reset the unit.
FEATURES AND CONTROLS OPENING THE NET 1. To exit the vehicle, release the top front latch. 2. Rotate the net rearward and slide the lower net rod out of the mount to remove it. 3. Allow the net to hang freely outside the vehicle while dismounting. ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.
FEATURES AND CONTROLS HITCH AND TRAILER CONNECTOR (ZUGMASCHINE MODELS ONLY) WARNING Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object. REAR HITCH Use the rear hitch for towing a trailer. REAR HITCH SPECIFICATIONS Material S355J2+N Fasteners Metal pin with security cotter pin Weld Length and Positions 7 mm fillet, all around Maximum Vertical Load 100 kg applied on coupling point Maximum Towable Mass 1000 kg Approval # E9-55R-01.
FEATURES AND CONTROLS HITCH REMOVAL / INSTALLATION 1. To remove the hitch, remove the cotter pin and hitch pin. Remove the hitch, then reinstall the hitch pin and secure the cotter pin. Cotter Pin q Hitch Pin w Step 4 Step 5 2. To install the hitch, remove the cotter pin from the hitch pin and remove the hitch pin. 3. Install the hitch to the receiver. 4. Reinstall the hitch pin (from the left side of the hitch) through the bore of both the receiver and the hitch. 5. Reinstall the cotter pin.
FEATURES AND CONTROLS INSTRUMENT CLUSTER 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 speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
FEATURES AND CONTROLS TIP With the ignition key off, pressing the MODE button or either toggle button will power up the Rider Information Center for 10 seconds to allow viewing of the odometer and the clock. INDICATOR LAMPS LAMP INDICATES CONDITION Vehicle Speed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. 44 Over Temperature This lamp illuminates to indicate an overheated engine.
FEATURES AND CONTROLS LAMP INDICATES CONDITION Low Fuel This lamp illuminates when fuel level in the fuel tank is low. Speed Key (optional accessory) Information about the speed key is provided in the accessory kit.
FEATURES AND CONTROLS RIDER INFORMATION CENTER q Gear Indicator This indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park – = Gear Signal Error (or shifter between gears) w AWD Indicator This indicator shows whether 2X4 or AWD is active. e Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance.
FEATURES AND CONTROLS MODE INFORMATION DISPLAYS The rider information center contains three areas that display mode information. q Area 1 Modes Description Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) w Area 2 Modes Description Odometer The odometer records and displays the distance traveled by the vehicle. Trip Meters (T1/T2) A trip meter records the distance traveled by the vehicle if reset before each trip.
FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See page 47. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds. 1. Press and release either toggle button to cycle to the desired option. 2. Press MODE to select the option. 3. Press either toggle button to cycle to the desired setting. 4.
FEATURES AND CONTROLS BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “BL LEVEL” option. Press MODE to select. 3. Press “UP” button to increase brightness. Press “DOWN” button to decrease brightness. 4. Press MODE to select and exit to the settings menu. CLOCK The clock must be reset any time the battery has been disconnected or discharged. 1.
FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the desired “UNITS” option (distance, temperature or volume). Press MODE to select. 3. Press either toggle button to cycle to the desired setting. 4. Press MODE to save and exit to the settings menu. TRIP METER Use a trip meter to track the distance traveled during a specific trip or period of time. Reset the meter to zero before traveling. 1.
FEATURES AND CONTROLS PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory. As hours of engine operation increase, the counter decreases. The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset. When this feature is enabled, it provides a convenient reminder to perform routine maintenance.
FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine. If the CHECK ENGINE lamp or the EPS lamp illuminates, retrieve the active error codes from the display. q Failure Mode Indicator (FMI) w Suspect Parameter Number (SPN) e Code Count 1.
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. VEHICLE BREAK-IN PERIOD The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 tanks full of gasoline.
OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads.
OPERATION SAFE OPERATION PRACTICES 1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751. 2. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle. 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5.
OPERATION PRE-RIDE INSPECTION WARNING 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 ITEM REMARKS PAGE Cab Doors (if equipped) Check doors and latches for wear or damage. - Grass and leaves Remove grass, leaves, and other flammable material or debris, especially near the exhaust system. - STARTING THE ENGINE 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Always make sure all cab doors are closed and latched when riding in this vehicle. 3. Place the transmission in PARK or NEUTRAL. 4.
OPERATION STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. WARNING A rolling vehicle can cause serious injury. Always place the transmission in PARK when stopping the engine. COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently.
OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. BELT LIFE To extend belt life, use low gear when hauling or towing heavy cargo.
OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 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. Shift the gear selector to the Park position. 4. Turn the key to the off position. 5. Dismount vehicle. 6. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 7. Open the tailgate. 8. Stand clear and pull up on the cargo box release lever. 9.
OPERATION ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential. ENGAGING AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage. Always switch to AWD while the rear wheels have traction or are at rest. q All-Wheel Drive (AWD) w Differential Lock e Differential Unlock Press the top of the switch to engage All Wheel Drive (AWD).
OPERATION DISENGAGING AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction. In some situations, the front gearcase may remain locked after turning the AWD switch off. If this occurs, you may notice increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gearcase. To disengage AWD, do the following: 1.
OPERATION UNLOCKING THE DIFFERENTIAL (TURF MODE) When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Always operate in AWD on these types of terrain.
OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA. 3. Perform the pre-ride inspection. 4. Do not tow or carry cargo during this period. 5.
OPERATION • Never turn while applying heavy throttle. • Never make abrupt steering maneuvers. • Operate at speeds appropriate for your skills, the conditions and the terrain. • DO NOT do power slides, “donuts”, jumps or other driving stunts. DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 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.
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 OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Move the drive mode switch to low mode if needed. 5.
OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Avoid excessively steep hills. 2. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. 3. Drive straight downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible. 4. Slow down. 5. Apply the brakes slightly to aid in slowing.
OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 112, 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. Never open the throttle suddenly. PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2.
OPERATION PARKING ON AN INCLINE Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Engage the park brake. 4. Turn the engine off. 5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6. Block the rear wheels on the downhill side. BOARDING AND EXITING THE VEHICLE • • • • Never try to climb onto or exit the vehicle while it is moving.
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 WINCH CABLE CARE For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person. WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.
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.
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EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. SPARK ARRESTER Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.
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MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE 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 MAINTENANCE CHART KEY SYMBOL DESCRIPTION XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized dealer or other qualified person perform these services. WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized dealer or other qualified person perform these services.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS CLNDR KM (MILES) Engine Breather 50 H 6M 800 (500) Inspect; replace as needed Shift Linkage 50 H 6M 800 (500) Inspect, lubricate, adjust D Steering 50 H 6M 800 (500) Lubricate XU Front / Rear Stabilizer Bars 50 H 6M 800 (500) Lubricate and inspect bushings D Throttle Pedal 50 H 6M 800 (500) Inspect; adjust; lubricate; replace as needed Throttle Body Intake Ducts/Flange 50 H 6M 800 (500) Inspect du
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS CLNDR KM (MILES) D Wheel Bearings 100 H 12 M XU Shock Seals 100 H - Ratcheting Cam Chain Tensioner 200 H - Brake Fluid 200 H 24 M 3200 (2000) Change every two years Suspension Bushings 250 H 24 M 3200 (2000) Inspect; replace if necessary Spark Arrestor 300 H 36 M 4800 (3000) Clean out D D 1600 (1000) Inspect; replace as needed - Visually inspect shock seals 3200 (2000) Check; replace as needed Toe Adj
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS CLNDR KM (MILES) - Visually inspect shock seals XU Shock Seals 100 H - D Valve Clearance 150 H - DXU Clutches (Drive and Driven) 200 H 12 M Ratcheting Cam Chain Tensioner 200 H - Brake Fluid 200 H 24 M 3200 (2000) Change every two years Suspension Bushings 250 H 24 M 3200 (2000) Inspect; replace if necessary Spark Arrestor 300 H 36 M 4800 (3000) Clean out D D 5000 (3125) Inspect; adjust as needed 32
MAINTENANCE ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil. Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause.
MAINTENANCE OIL CHECK The oil dipstick is located on the engine. Access the dipstick through the right rear wheel well. To check the oil, do the following: 1. Position vehicle on a level surface and place the transmission in PARK. 2. Stop the engine and allow it to cool down before removing the dipstick. 3. Raise the cargo box. Unlock the dipstick lever q. Remove the dipstick and wipe it dry with a clean cloth. 4. Reinstall the dipstick and push it into place. Do not lock the dipstick.
MAINTENANCE ENGINE OIL AND FILTER REPLACEMENT Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover. Access the oil dipstick and oil fill cap by tilting the rear cargo box. The crankcase drain plug is located on the bottom of the crankcase.
MAINTENANCE 8. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification. TORQUE Oil Filter: Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn. 10. Replace the sealing washer on drain plug.
MAINTENANCE 21. Dispose of used oil and filter properly. GEARCASES GEARCASE SPECIFICATION CHART CAPACITY FILL PLUG TORQUE DRAIN PLUG/ LEVEL CHECK PLUG TORQUE GEARCASE LUBRICANT Transmission (Main Gearcase) AGL Gearcase Lubricant & Transmission Fluid 41 oz. (1200 ml) 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) Demand Drive Unit (Front Gearcase) Demand Drive Fluid 9.3 oz. (275 ml) 8-10 ft. lbs. (11-13.6 Nm) 11 ft. lbs.
MAINTENANCE TRANSMISSION OIL CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate. 1. Remove the fill plug q. 2. Place a drain pan under the drain plug w. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean and reinstall the drain plug. Torque to specification. 5. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill. 6. Reinstall the fill plug. Torque to specification. 7. Check for leaks.
MAINTENANCE DEMAND DRIVE OIL CHANGE 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the passenger's side. 3. Remove the fill plug. 4. Place a drain pan under the drain plug w on the bottom right-hand side. 5. Remove the drain plug. Drain the oil. 6. Clean and reinstall the drain plug. Torque to specification. 7. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10.
MAINTENANCE SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. CAUTION A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. To inspect the spark plugs, do the following: 1. Lift the cargo box to access the spark plugs. 2.
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 RADIATOR COOLANT LEVEL Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequentially, engine damage. 1. Lift the hood. CAUTION Escaping steam can cause burns.
MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. 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 surface. 2. Lift the hood. View the coolant level in the overflow bottle w. 3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid.
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 BELT REMOVAL If a belt fails, always clean any debris from the clutch air 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. NOTE Inspect the entire clutch outlet duct (including the outlet duct screen) when replacing a drive belt. Remove any debris found in the outlet duct or outlet duct screen.
MAINTENANCE 3. Rotate the clutch cover back and lift up and over the control arm mounting w. NOTE Use care when lifting clutch cover upwards. Do not damage cover, intake boot, or electrical harness. 4. Pull clutch cover out towards the rear of the vehicle as shown above. 5. Mark the drive belt direction of rotation so that it can be installed in the same direction.
MAINTENANCE 6. Insert clutch spreader tool e into threaded hole on driven clutch as shown and turn clockwise to spread clutch. NOTE Clutch spreader tool part number 2875911 is found in vehicle tool kit. 7. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. BELT INSPECTION To inspect the drive belt, do the following: 1. Inspect belt for hour-glassing (extreme circular wear in at least one spot and on both sides of the belt).
MAINTENANCE BELT INSTALLATION NOTE Be sure to install belt in the same direction as it was removed. 1. With the clutch spreader tool q installed, loop the belt over the drive clutch and over the driven clutch. 2. Rotate the driven clutch and walk the belt into the clutch. 3. Remove the clutch spreader tool from driven clutch. 4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch. 5. Install the clutch cover into wheel well as shown above. 6.
MAINTENANCE 8. Install and torque the outer clutch cover bolts to specification.
MAINTENANCE POLARIS VARIABLE TRANSMISSION (PVT) DRYING There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Position the vehicle on a level surface. 2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug. 3. Place the transmission in PARK. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.
MAINTENANCE FILTER SYSTEMS AIR FILTER REPLACEMENT Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often. 1. Tilt the rear cargo box to access the airbox. 2. Release the three airbox cover latches and lift the cover up and out to access the air filter element. 3. Remove the air filter element q.
MAINTENANCE 4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel. NOTE If the filter has been soaked with fuel or oil it must be replaced. DO NOT attempt to clean the air filter. 5. Place the air filter into the airbox. Reposition the lower airbox cover and install the three retaining latches.
MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time. • Do NOT perform service on the spark arrester while the system is HOT.
MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE 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. 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 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 positionsq. 2. Reposition the shocks to the outside mounting holesw. 3. Reinstall the shock mounting bolts. Torque to 40 ft-lbs (54.2 Nm).
MAINTENANCE CAM 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 POSITION BULB AND INDICATOR BULB REPLACEMENT 1. Remove the hood from the front cab. 2. Locate the bulb on the back side of the headlight housing. 3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring. 4. Turn the bulb counterclockwise and remove it from the headlight housing. 5. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place. NOTE Make sure the tab on the bulb locates properly in the housing. 6.
MAINTENANCE HIGH/LOW BULB REPLACEMENT 1. Remove the hood from the front cab. 2. Locate the High/Low bulb on the back side of the headlight housing. 3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring. 4. Remove the rubber bulb cover, release the bulb protection spring q and remove the bulb from the headlight housing. 5. Install the new bulb into the housing. NOTE Make sure the tab on the bulb locates properly in the housing. 6.
MAINTENANCE HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 1. Place the vehicle on a level surface with the headlight approximately 7.6 m ( 25 ft) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. Turn on the headlights. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 20 cm (8") below the mark placed on the wall.
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 WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
MAINTENANCE BATTERY REMOVAL WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. To remove the battery, do the following: 1. Remove the storage bin under the passenger seat to access the battery. 2. On conventional batteries, remove the battery vent tube. 3.
MAINTENANCE BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow instructions in the Battery Charging (Conventional Battery) section before installing the battery. An optional extreme use battery may be available for your model.
MAINTENANCE BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. TIP Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge.
MAINTENANCE 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. TIP When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines below for recharging. Always verify battery condition before and 1-2 hours after the end of charging.
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 • Electrical components and wiring • Air intake components If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer, or other qualified person, to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. 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.
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. STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers.
MAINTENANCE FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
MAINTENANCE 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. 4. Remove the key to prevent loss during transporting. 5. Secure the fuel cap and seat. Ensure that the seat is attached correctly and is not loose. WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle.
MAINTENANCE FRONT TIE-DOWN LOCATION q Front tie-down points 134
MAINTENANCE REAR TIE-DOWN LOCATION w Rear tie-down points TOWING A RANGER Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 16 km/h (10 MPH).
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SPECIFICATIONS SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) 738 kg (1627 lbs.) Dry Weight 714 kg (1574 lbs.) Test GVW - Rollover Protection System (ROPS) Fuel Capacity 1542 kg (3400 lbs.) per OSHA 29 CFR 1928.53 43.9 l (11.6 gal) Engine Oil Capacity 2.4 l (2.5 qts) Coolant Capacity 4.75 l (5 qts.) Overall Length 305 cm (120 in.) Overall Width 159 cm (62.5 in.) Overall Height 195 cm (77 in.
SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Compression Ratio 10.8:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32° +/- 2° @ 5000 RPM Spark Plug/ Gap Lubrication System Cooling MR7F / 0.7-0.8 mm Wet Sump Liquid Front Suspension Dual A-Arm, IRS 27.94 cm (11.0 in) Travel Rear Suspension Dual A-Arm 27.94 cm (11.0 in) Travel Ignition System Driving System Type Shift Type Digital CDI PVT Single Lever (H/L/N/R/P) Gear Reduction - Low Front 9.
SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.
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POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PRODUCT SIZE (QUANTITY) PART NUMBER 12 oz aerosol (12) 2870791 1 qt (12) 2871517 1 qt (12) 2876244 2 qt (8) 2877490 Fogging Oil PS-4 PS-4 Extreme Duty 1 gal (4) 2876245 1 qt (12) 2878920 2 qt (8) 2878922 1 gal (4) 2878919 1 qt (12) 2878068 1 gal (4) 2878069 AGL Pump for Gallon Jug 3.8 l 2870465 1 qt (12) 2877922 2.
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TROUBLESHOOTING 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. 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 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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7-Way Trailer Connector . . . . . . . . . . . . . 42 A Adding or Changing Coolant . . . . . . 100 Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 20 Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 131 Air Intake Maintenance Air Filter Replacement . . . . . . . . . . . . 110 All Wheel Drive/Rear Differential System . . . . . . . . . . . . . . . . . . . 62 Auxiliary Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . 34 Axle and Wheel Nut Torque Specifications. . . . . .
Engine Stops or Loses Power . . . . 147 Engine Turns Over, Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Equipment Modifications . . . . . . . . . . . . . 27 Error Codes, Engine. . . . . . . . . . . . . . . . . . . 52 Exhaust Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Exported Products . . . . . . . . . . . . . . . . . . . 153 Exposure to Exhaust . . . . . . . . . . . . . . . . . . 26 Eye Protection . . . . . .
Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Oil Recommendations . . . . . . . . . . . . . . . . 92 Operating Improperly in Reverse. . . 24 Operating Over Obstacles . . . . . . . . . . . 25 Operating Through Water . . . . . . . . . . . . 25 Operating With a Load on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . 17 Overflow Bottle Coolant Level . . . . 102 P Park Brake Lever.
U Unauthorized Use of the Vehicle . . . 27 V Vehicle Immersion . . . . . . . . . . . . . . . . . . . 109 W Warranty Coverage And Exclusions Lubricants and Fluids . . . . . . . . . . . . 151 Washing the Vehicle. . . . . . . . . . . . . . . . . 129 Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . . . 99 Wheel Installation . . . . . . . . . . . . . . . . . . . . . 118 Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . . 118 Winch Cable Care . . . . . . . . . . . . . . . . . . . . .
PMS 419 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Place de l’Industrie 2 1180 Rolle, Switzerland Part No.
