WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 23 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 51 MAINTENANCE AND LUBRICATION . . . . . . . . . 53 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 101 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
Operator Safety SAFETY WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Operator Safety SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully. Follow the operating procedures described. S Never allow anyone without a valid driver’s license to operate this vehicle. S Minimum age recommendation for passengers is five years old.
SAFETY Operator Safety S Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. S Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.
Operator Safety SAFETY S Never modify this vehicle through improper installation or use of accessories. S Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. S Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.
SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Lock the parking brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways. WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.
Operator Safety SAFETY WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. CAUTION Always keep combustible materials away from the exhaust system.
SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection. Read and follow the instructions of the decals on the RANGER carefully. If any of the decals depicted in this manual differ from the decals on your RANGER, always read and follow the instructions of the decals on the RANGER. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations 4 1 3 2 WARNING WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Remove flammable containers from box before refueling. WARNING Maximum Box Load is ___ lbs. Location 4 (inside front of box) Fuel / Passenger Warning Decal Text Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers in cargo box.
SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: 5 VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE USAGE GENERAL VEHICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS. 7078472 Location 5 (under hood) 6 ATTENTION S Operation of this vehicle without the filter element will severely damage the engine.
SAFETY Safety Decals and Locations Discretionary Warning Decal 7 WARNING 7172675 Location 8 8 Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or while operating this vehicle. S Operate at speeds too fast for your skills or the conditions. S Operate this vehicle on HILLS steeper than 15 degrees.
SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck.
FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Component Locations 1 4 2 3 5 6 9 7 1. 2. 3. 4. 5. 6. 7. 8. 9.
FEATURES AND CONTROLS Component Locations 10 13 12 10. 11. 12. 13.
FEATURES AND CONTROLS Component Locations 16 15 14 14 17 20 18 14. 15. 16. 17. 18. 19. 20.
FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display: 6 4 1. High Gear 2. Low Gear (if equipped) 3. Neutral Gear 4. Reverse Gear 5. High Temperature 6. Brakes Trailer Hitch Bracket 2 5 1 3 This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on page 47.
Seat Removal FEATURES AND CONTROLS Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets. Seat Belts The RANGER is equipped with lap-style seat belts for the operator and passenger. WARNING Falling from a moving vehicle could result in serious injury or death.
FEATURES AND CONTROLS Console 3 2 1 4 5 6 1 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
FEATURES AND CONTROLS Gear Selector (1) RANGER 2X4, 4X4 H: High Gear L: Low Gear N: Neutral R: Reverse H RANGER TM H: High Gear N: Neutral R: Reverse H NOTE: 1 L N R N R Low is the primary driving range for the RANGER 2X4 and 4X4. High is intended for use on hard-packed surfaces with light loads. To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
FEATURES AND CONTROLS 2 A D AWD 3 1 4 B E C F 2WD Ignition Switch (1) The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF The engine is off. Electrical circuits are off, except Acc. 12V. ON Electrical circuits are on. Electrical equipment can be used. START Turn the key to the START position to engage the electric starter. The key returns to the ON position when released.
Brake Pedal (1) FEATURES AND CONTROLS Depress the brake pedal to slow or stop the vehicle. Throttle Pedal (2) Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there’s adequate throttle pedal freeplay. See page 85 for throttle pedal adjustment procedures.
OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.
OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. Starting a Cold Engine 1. Place the transmission in neutral. 2. Lock the parking brake. 3. Sit in the driver’s seat and fasten the seat belt.
Starting the Engine OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake. 3. Sit in the driver’s seat and fasten the seat belt. 4. Turn the ignition key to START. 5. If the engine has cooled and does not readily start, intermittent use of the choke knob (pulled half way out) may be necessary. 6.
OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you’re familiar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking. WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury.
Driving Safely OPERATION Driving Procedures 1. Sit in the driver’s seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving.
OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. 4.
OPERATION Driving Safely Driving Uphill 15_ Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15_ maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill. Braking and handling are greatly affected when operating in hilly terrain.
OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15_ maximum). Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brakes slightly to aid in slowing.
Driving Safely OPERATION Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1). Follow these procedures when operating through water: 1. Always determine water depths and current before entering. 2.
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Reduce speed and travel with caution in unfamiliar terrain.
Driving Safely OPERATION Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision before backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. Always block the downhill side of the wheels if leaving the vehicle on a hill, or park the vehicle in a sidehill position instead.
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: Always load the cargo box with the load as far forward as possible. Always operate the vehicle with extreme care when hauling or towing loads. Slow down and drive in the lowest gear available. The RANGER has been designed to carry or tow specific capacities.
OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position. 1. Select a level site to dump the cargo box.
OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. Towing a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle.
OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition switch key to prevent unauthorized use. WARNING Gasoline is extremely flammable and can be explosive under certain conditions.
OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential. On AWD models, engaging AWD locks the front differential and the rear differential. CAUTION 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. AWD (4X4) When in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed.
OPERATION All Wheel Drive (AWD) When in AWD, the front gearcase will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100.
EMISSION CONTROL SYSTEMS Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " E J Perform these procedures more frequently for vehicles subjected to severe use. Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks " Engine breather 25 H Monthly -- Inspect; replace if necessary " Engine oil change 25 H 1M -- Perform a break-in oil change at one month " General 50 H 3M -- Lubricate all fittings, pivots, cables, etc.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) J Fuel system 100 H 12 M -- J Fuel filter 100 H 12 M -- " Radiator 100 H 12 M -- Inspect; clean external surfaces " Cooling hoses 100 H 12 M -- Inspect for leaks " Engine mounts 100 H 12 M -- Inspect 100 H 12 M -- Inspect J Spark plug 100 H 12 M -- Inspect; replace as needed J Ignition Timing 100 H 12 M -- Inspect " Wiring 100 H
MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More often under severe use, such as wet or dusty conditions F No.
MAINTENANCE AND LUBRICATION Lubrication Recommendations TM (2) TM (1) 4X4 59
MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
MAINTENANCE AND LUBRICATION Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check (2x4, 4X4) The oil tank is located under the seat. 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat (see page 27). 4. Remove the dipstick (1) and wipe it dry with a clean cloth. 5.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) CAUTION Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin. 1. Run the engine two to three minutes until warm. Stop the engine. 2. Clean the area around the drain plug (1) at the bottom of the oil tank. 2 3. Place a drain pan beneath the 1 oil tank and remove the drain plug. Allow the oil to drain 4 completely. 4. Install a new sealing washer (2) on the oil drain plug.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) 8. Reattach the oil line. 9. Place shop towels beneath the oil filter (5). Using an oil filter wrench, turn the filter counterclockwise to remove. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the 5 engine. 12.
MAINTENANCE AND LUBRICATION Engine Oil Oil Pump Priming (2x4, 4X4) This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent line’s pressure relief slit (3). 2. Run the engine for 15-20 seconds. 3. Remove the vent line clamp. The oil pump will now be properly primed and ready for operation.
MAINTENANCE AND LUBRICATION Engine Oil Oil Check (TM) 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 27. Remove the service panel (1) by pulling upward. 4. Remove the dipstick (2) and wipe it dry with a clean cloth. 5. Replace the dipstick and seat it completely. 6. Remove the dipstick and check to see that the oil level is between the FULL (3) and ADD (4) marks.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 1. Position the vehicle on a level surface. 2. Run the engine two to three minutes until warm, then stop the engine. 3. Clean the area around the drain plug (6) at the bottom of the engine. The plug is accessible through the access hole in the bottom of the skid plate. CAUTION Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin. 4. Place a drain pan beneath the engine and remove the drain plug.
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 7. Place shop towels beneath the oil filter (1). Using an oil filter wrench (2), turn the filter counterclockwise to remove. 8. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 9. Check to make sure the o-ring (3) is in good condition. Lubricate the o-ring on the new filter with a film of engine oil. 10.
MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase (Transmission) (4X4) Premium AGL Synthetic Gearcase Lube 15.2 oz. (450 ml) 14 ft. lbs. (19.4 Nm) 14 ft. lbs. (19.4 Nm) Main Gearcase (Transmission) (2X4, TM) Premium AGL Synthetic Gearcase Lube 18.2 oz. (540 ml) 14 ft. lbs. (19.4 Nm) 14 ft. lbs. (19.4 Nm) Front Gearcase (4X4) Premium Demand Drive Hub Fluid 5 oz. (150 ml) 8-10 ft. lbs. (11-13.
MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom of the fill plug hole. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 101 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. 2. Remove the fill plug (1), which is located on the rear of the vehicle.
MAINTENANCE AND LUBRICATION Gearcases Front Gearcase (4X4) Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of Polaris Premium Demand Drive Hub Fluid. See page 101 for the part numbers of Polaris products. The front gearcase fill plug (1) is located on the right side of the front gearcase. Oil Check 1.
MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of Polaris ATV Angle Drive Fluid. See page 101 for the part numbers of Polaris products. The rear gearcase fill plug (1) is on the driver’s side of the rear gearcase. Oil Check 1. Position the vehicle on a level surface. 2.
MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.
MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 1. Lift the hood and slowly remove the radiator cap (1). 2. View the coolant level through the opening. 3.
MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER 2X4, 4X4 .025″ (.06 cm) 9-11 ft. lbs. (12-15 Nm) 9-11 ft. lbs. (12-15 Nm) RANGER TM .025″ (.06 cm) 8.7-10.8 ft. lbs. (11.8-14.6 Nm) 16.6-19.5 ft. lbs. (22.5-26.
MAINTENANCE AND LUBRICATION 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 AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your RANGER to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land, or at the very least, to a water level below the floor. 2. Disconnect the fuel pump wires. 3. Remove the spark plug. 4.
MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Lift the cargo box to access the air box. 1 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter (1). 4. Do not attempt to clean the main element. Install a new air filter.
MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line (1) out the side of the air box and locate the filter (2). 3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace as needed. 4. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE AND LUBRICATION Filter Systems (TM) Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Remove the seat to access the air cleaner. 2. Remove the breather hose (1) from the cylinder. 3. Remove the wing nut (2) and remove the air cleaner cover (3). 4. Remove the primary filter (4) and the secondary filter (5). NOTE: Do not attempt to clean the primary filter. Install new. 5.
MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. Recommended engine idle RPM for the RANGER TM is 1000 +/- 100. If the engine idle speed is not satisfactory, 2X4 and all other conditions are favorable, the 4X4 carburetor can be adjusted with the following procedure. 1.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging.
MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge accumulated carbon from the system by 2 1 momentarily revving the engine several times. 4.
MAINTENANCE AND LUBRICATION Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.
MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Inspection 1. Apply the parking brake (2) and shift the transmission to neutral. 2. Start the engine and warm it up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches. Throttle Freeplay Adjustment 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2.
MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation. Change the brake fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.
Brakes MAINTENANCE AND LUBRICATION Brake Inspection 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. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when worn to 3/64″ (.1 cm). 3/64″ (.1 cm) Parking Brake Inspection 1. Slowly push the parking brake down with your foot. 2. After 8 to 12 clicks of lever travel, check the vehicle for movement.
MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play. 4.
MAINTENANCE AND LUBRICATION Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it’s securely latched. 2. Push the red button in the middle of the buckle to make sure it releases freely. 3. Check the belt webbing for wear, cuts or damage.
MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
Tires MAINTENANCE AND LUBRICATION WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3.
MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin.
Lights MAINTENANCE AND LUBRICATION Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and switch on the headlight. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8″ (20.3 cm) below the mark placed on the wall in step 2.
MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2 2. Reach in behind the console 1 panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the console panel. 4. Using a screwdriver, turn the light that needs to be replaced 1/4 turn counterclockwise. 5. Grip the light with a needle nose plier and remove the light from the assembly. 6.
MAINTENANCE AND LUBRICATION Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last.
MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder. Operate the starter for a few seconds and reinstall the spark plug. 3. Remove the battery. Store it in a cool, dry place out of the sun. 4.
MAINTENANCE AND LUBRICATION Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it’s not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 33.
MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery. WARNING Battery electrolyte is poisonous. It contains sulfuric acid.
Battery MAINTENANCE AND LUBRICATION Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the 1 upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery. WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death.
MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte as severe burns could result. 3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5.
POLARIS PRODUCTS Part No. Description 2870791 2871281 2871844 Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2873602 2873603 2871653 2872276 2870465 2871654 2872277 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (qt.) Premium AGL Synthetic Gearcase Lube (gal.) Premium ATV Angle Drive Fluid (8 oz.) Premium ATV Angle Drive Fluid (2.5 gal.
SPECIFICATIONS RANGER TM Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug 102 2400 lbs. (1089 kg) 8.5 gal.
SPECIFICATIONS RANGER TM Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: Full Pressure 0W/40 PVT Single Lever (console) NA 6.84:1 4.71:1 NA 3.
SPECIFICATIONS RANGER 2x4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug 104 2500 lbs. (1135 kg) 8.5 gal.
SPECIFICATIONS RANGER 2x4 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights/Brake Light Indicator Light NOTE: Dry Sump 0W/40 PVT Single Lever (console) 8.71:1 5.9:1 3.83:1 NA 3.
SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug 106 2700 lbs. (1226 kg) 8.5 gal.
SPECIFICATIONS RANGER 4X4 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: Dry Sump 0W/40 PVT Single Lever (console) 8.71:1 5.9:1 3.83:1 3.83:1 3.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connectio
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris RANGER against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2005 and later Large Spark Ignition Engine (herein “LSI engine”).
WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the original retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.
WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) " Engine oil level -- Pre-Ride -- Make adjustments as needed. See Pre-Ride Checklist on page 33.
WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emission-related parts. These replacement parts will be provided at no charge if the part is still under warranty.
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 121
INDEX A D Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Filter (2x4, 4X4) . . . . . . . . . . . . . 78 Air Filter (TM) . . . . . . . . . . . . . . . . . 80 All Wheel Drive (AWD) . . . . . . . . 49-50 Auxiliary Outlet . . . . . . . . . . . . . . . . 26 AWD Switch (4X4) . . . . . . . . . . . . . 30 Driving Through Water . . . . . . . . . . . 41 Driving Uphill . . . . . . . . . . . . . . . . . 39 Dumping the Cargo Box . . . . . . . . . . 46 B Battery . . . . . . . . . . . . . . . . . . . .
INDEX N S Noise Emission Control System . . . . 52 Spark Arrestor . . . . . . . . . . . . . . . . 82-83 Spark Plugs . . . . . . . . . . . . . . . . . . . . 75 Specifications . . . . . . . . . . . . . . 102-107 Starting a Cold Engine . . . . . . . . . . . 34 Starting a Warm Engine . . . . . . . . . . 35 Starting the Engine . . . . . . . . . . . . 34-35 Steering Wheel Inspection . . . . . . . . 88 Stopping the Engine . . . . . . . . . . . . . 35 Storage . . . . . . . . . . . . . . . . . . . . . . .
