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2014-12-11

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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. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

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. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 RANGER XP 4X4 700 EFI/RANGER 6X6 700 EFI
Owner’s Manual P/N 9920220

TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FEATURES AND CONTROLS . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 52
MAINTENANCE AND LUBRICATION . . . . . . . . . 53
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . 99
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 100
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 104
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . 116
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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.

31XX

Vehicle Model Number:
(behind left front wheel)
Frame VIN (1):
(under hood)
Engine Serial Number (2):
(right front side of engine crankcase)
Key Number (3):

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.
Read and understand your owner’s manual and all warnings
before operating the vehicle.

Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may
ride as a passenger in this vehicle.

Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

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.

CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.

CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.

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. Passengers under five years of age require special restraints which are
not available with this vehicle. Driver and passenger should wear
their seat belts at all times.
S Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
S To reduce tipover risk, be especially careful when encountering obstacles and slopes and when braking on hills or during turns.
S This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
S Helmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
S Never consume alcohol or drugs before or while operating this vehicle.
S Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your vehicle each time you use it to make sure it’s in
safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
S Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.
S Never operate on excessively rough, slippery or loose terrain.

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.
S Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.
S Always follow the proper procedures outlined in this manual for
traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed.
Avoid going downhill at an angle, which would cause the vehicle to
lean sharply to one side. Travel straight down the hill where possible.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
S Always be careful of skidding or sliding. On slippery surfaces such
as ice, travel slowly and exercise caution to reduce the chance of
skidding or sliding out of control.
S Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced
stopping ability. Test your brakes after leaving water. If necessary,
apply them lightly several times to let friction dry out the pads.
S Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it’s safe to proceed in reverse,
move slowly. Avoid turning at sharp angles in reverse.
S Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on page 19.

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.
S Always keep arms and legs inside the cab frame while the vehicle is
in motion.
S Always engage the park brake before getting out of the vehicle. See
page 32.
S Always apply the service brakes before releasing the park brake.
S Always turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks.
Gasoline is extremely flammable. See page 22 for refueling instructions.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at
1-800-342-3764.

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. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
Do not make any modifications to your RANGER.

Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris RANGER any equipment that may increase the
speed or power of the vehicle, or make any other modifications to the
vehicle for these purposes. Any modifications to the original
equipment of the vehicle create a substantial safety hazard and increase
the risk of bodily injury.
The warranty on your Polaris RANGER is terminated if any equipment
has been added to the vehicle, or if any modifications have been made
to the vehicle, that increase its speed or power.
NOTE:

The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.

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.
Engage the park brake after fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service dealer check
the complete vehicle for possible damage, including (but not
limited to) brakes, throttle and steering.

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.

WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the operator does
not know 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.

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.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving a RANGER requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving. They
will reduce your alertness and slow your reaction time. In most
states and provinces, it’s prohibited by law to drive while
intoxicated or under the influence of drugs.

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.

WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator
fall through the ice.
HOW TO AVOID THE HAZARD
Never operate the RANGER on a frozen body of water.

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.

WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on
unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating the
vehicle. You may come upon hidden rocks, bumps, or holes
suddenly, without enough time to react.

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.

WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or
uneven tire pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified in the Owner’s
Manual for this vehicle. See page 19.
Always maintain proper tire pressure as described on the decal
and in the Owner’s Manual. See page 19.

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. Exposure to the hot components could result in a fire.

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. The part number is printed on the decal.
3
2

WARNING
S Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle
with guard removed.
S Do not modify engine or clutch. Doing so can
cause part failure, possible imbalance, and
excessive engine RPM, which can result in serious
injury or death.

NO STEP
Location 1
18

7172563

Safety Decals and Locations

SAFETY

WARNING
S VEHICLE ROLLOVER could cause severe injury or death.
This cab frame is not designed or intended to provide rollover protection.
S ALWAYS WEAR YOUR SEAT BELT for maximum protection.
7172676

Location 2

Location 3 (inside front of box)

Container/Passenger/Tire Pressure Warning Decal Text
Remove flammable material containers from box before filling.
S Passengers can be thrown off. This can cause serious injury or death.
S Never carry passengers in cargo box.
Maximum 2X4 Box Load 850 lbs. Maximum 4X4 Box Load 1000 lbs.
Maximum 6X6 Box Load 1200 lbs.
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI):
RANGER - 2x4 and 4x4 FRONT 10 REAR 10
RANGER - 6x6 FRONT 10 CENTER 10 REAR 10
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO:
RANGER 2X4 and 4X4 is 2750 LBS. RANGER 6X6 is 2900 LBS.
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your
risk of losing control. Loads should be centered and carried as low as possible
in box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful
if load extends over the side of the box.
Read Owner’s Manual for more detailed loading information.

SAFETY

Safety Decals and Locations

Location 5 (under hood)
6

ATTENTION
S Operation of this vehicle without the air filter
element will severely damage the engine.
S Clean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle without
pre-filter.

7172921

Location 6

Location 7
20

SAFETY

Safety Decals and Locations
Discretionary Warning Decal
7

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.
If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline
powered engine exhaust fumes are poisonous and can cause
loss of consciousness and death in a short time.

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 100.

Component Locations
1

4
2

7
10

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Cab Frame (if equipped)
Hip Bar
Console
Steering Wheel
Seat
Storage Box (under driver’s seat)
Cargo Box
Seat Belts
Fuel Tank Cap / Fuel Gauge
Battery (under hood)
Storage Box (under hood)

FEATURES AND CONTROLS
Component Locations

15
14

12.
13.
14.
15.

Headlights
Radiator (if equipped)
Front Bumper/Brush Guard
Hood Hold Down Strap

FEATURES AND CONTROLS

Component Locations

22
20

16.
17.
18.
19.
20.
21.
22.

21
20

Taillights
Tailgate
Tailgate Latch Release
Muffler (Spark Arrester)
CV Boot/Rear Caliper
Air Box
Receiver Hitch

FEATURES AND CONTROLS
Indicator Lights
1.
2.
3.
4.
5.
6.

High Gear
Low Gear
Neutral Gear
Reverse Gear
High Temperature
Park Brake

Trailer Hitch Bracket

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 48.

Auxiliary Outlet
The 12-volt receptacle (7)
has spade connections on
the back that may be used to
power an auxiliary light or
other optional accessories or
lights. The connections are
behind the console, under
the hood.

FEATURES AND CONTROLS

Fuel Cap/Fuel Gauge

The fuel tank filler cap (8) is located on
the right-hand side of the vehicle near
the passenger seat. It has a built-in fuel
gauge that indicates the amount of fuel
remaining in the tank.
When the indicator needle nears the E
(empty) mark, refuel at the earliest
opportunity.
When refueling, always use either
leaded or unleaded gasoline with a
minimum pump octane number of 87
R+ M/2 octane.

Seat Removal

Pull up on the front of the seat
and slide it toward the front of
the vehicle.
Install the seat by sliding the
tabs into the rear of the seat
base. Push down firmly on the
front of the seat until the pins
are fully seated into the
grommets.

FEATURES AND CONTROLS
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. Always fasten your seat belt securely before operating or
riding in the RANGER.
Passengers under five years of age require special restraints,
which are not available with this vehicle. No person under the age
of five years may ride in the RANGER.

To wear the seat belt properly, follow this procedure:
1. Place the belt across your lap as low on your hips as possible,
taking care that the belt is not twisted.
2. Push the latch plate into the buckle until it clicks.
3. Release the strap, it will self tighten.
NOTE:

The center belt must be tightened manually by pulling on the
strap.

To unfasten, press the square red button in the buckle’s center.

Console
2

FEATURES AND CONTROLS
3

6
1

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Cup Holder
Indicator Lights
Shift Lever
Light Switch
AWD/Differential Switch (if equipped)
Hour Meter
Glove Box with Lid
12V Accessory Plug
Storage Tray
Ignition Switch
Storage Box

FEATURES AND CONTROLS
Gear Selector
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
NOTE:

H
L
N
R

Low gear is the primary
driving range for the
RANGER XP. High gear 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.

CAUTION
Do not attempt to shift the transmission while the vehicle is
moving or damage to the transmission could result. Always shift
when the vehicle is stationary and the engine is at idle.
Always place the transmission in gear, engage the park brake
and turn the engine off whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting
problems.

Switches

FEATURES AND CONTROLS

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

Engine off. All electrical circuits
are off except Acc. 12V.

ON/RUN Electrical circuits are on.
Electrical equipment can be used.
START

Electric starter is engaged by
holding ignition switch key in this
position. Upon release, the key
will return to the ON/RUN
position.

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.

Light Switch (2)

The ignition switch key must be in the ON/RUN position
to operate the headlights. The switch has three
B
positions:
A: High Beam
C
B: Low Beam
C: Off

AWD/Differential Lock Switch (3)

AWD
The AWD/Differential Switch has three positions:
E
D: AWD
E: Differential Lock (2WD)
F: Off (1WD)
F
Press the top of the rocker switch to engage AWD.
See page 51 for AWD operating instructions.
Move the rocker switch to the center position to
lock the differential and return to 2WD. See page 50 for Differential
Lock operating instructions.
Press the bottom of the switch to unlock the differential and return to
1WD.

FEATURES AND CONTROLS
Brake Pedal (1)

Depress the brake pedal to slow or stop the vehicle.
Apply the brakes while starting the engine.

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 81 for throttle pedal
adjustment procedures.

1
4
2

Park Brake Pedal (3)

Engage the park brake when parking the vehicle to help prevent the
vehicle from rolling. To engage the park brake, apply the brakes, then
push the park brake pedal down firmly and fully with your foot.

Park Brake Release (4)
Always apply the service brakes before releasing the park brake. To
release the park brake, pull the park brake release handle. Make sure
the park brake pedal is functioning properly before each operation.

Vehicle Break-In Period

OPERATION

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.

CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.
Use of any oils other than those recommended by Polaris may
cause serious engine damage. We recommend the use of
Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on
page 22.
2. Check the oil level on the dipstick. See page 61. Add Polaris
Premium 4 Synthetic Oil if necessary to maintain the oil level in
the normal (safe) operating range.
3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 34.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 25
hours.

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.

Pre-Ride Checklist
Item

Remarks

See
Page

Brake system / lever travel

Ensure proper operation

Brake fluid

Ensure proper level

Front suspension

Inspect, lubricate if necessary

Rear suspension

Inspect, lubricate if necessary

Steering

Ensure free operation

Tires

Inspect condition and pressure

Wheels / fasteners

Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners

Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level

Ensure proper level

Coolant hoses

Inspect for leaks

Throttle

Ensure proper operation

Indicator lights / switches

Ensure operation

Air filter, pre-filter

Inspect, clean

Air box sediment tube

Drain deposits whenever visible

Headlamp

Check operation, apply Polaris dielectric grease when lamp is replaced
Check operation, apply Polaris dielectric grease when lamp is replaced

Brake light / tail lamp

-86,101
86
--

-32
26, 31
78
-88
89

Starting the Engine

OPERATION

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.

1.
2.
3.
4.

Sit in the driver’s seat and fasten the seat belt.
Engage the park brake.
Shift the transmission to neutral.
Apply the brakes while starting the engine.

NOTE:

Do not press the throttle pedal while starting the engine.

5. Turn the ignition key past the ON/RUN position to START.
Engage the starter for a maximum of five seconds. Release the key
when the engine starts.
6. If the engine does not start within five seconds, release the ignition
switch and wait five seconds. Repeat steps 5 and 6 until the engine
starts.
7. Vary the engine RPM slightly with the throttle to aid in warm up
until the engine idles smoothly.

CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.

OPERATION

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.
2. Turn the engine off.
3. Engage the park brake.

WARNING
A rolling vehicle can cause property damage and serious injury.
Always engage the park brake after stopping the engine.

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. Always
slow down and allow additional braking distance when towing or
hauling cargo.

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, apply the
service brakes, and shift the transmission into gear.
3. Check your surroundings and determine your path of travel.
4. Release the park brake.
5. Keeping both hands on the steering wheel, slowly release the
brakes and depress the throttle with your right foot to begin
driving.
6. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
NOTE:

Low gear is the primary range for operating the RANGER
XP. High gear is intended for use on hard-packed surfaces
with light loads.

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. Drive with AWD engaged (if equipped) to assist in controlling the
vehicle.

CAUTION
Severe damage to the drive train may occur if the AWD is
engaged while the wheels are spinning. Always allow the wheels
to stop spinning before engaging AWD.

WARNING
Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.
Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution when operating
on slippery surfaces.

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. Improper procedure could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (15_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly.
Never go over the crest of a hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.

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.

WARNING
Traveling downhill improperly could cause loss of control or
vehicle overturn. Always check the terrain carefully before
descending a hill.
Never descend a hill at high speed. Excessive speed may result
in loss of vehicle control and lead to serious injury or death.
Always operate slowly when traveling downhill.
Avoid descending a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight downhill when
possible.

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. Choose a crossing
where both banks have
1
gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles.
4. After leaving water, always dry the brakes by applying light
pressure to the pedal repeatedly until braking action is normal.
NOTE:

After running your vehicle in water, it’s critical that you
perform the services outlined in the Periodic Maintenance
Chart beginning on page 53. Give special attention to engine
oil, transmission oil, front and rear gearcases, and all grease
fittings.

CAUTION
Immersion can result in major damage if the vehicle isn’t serviced
correctly and promptly. After immersion, always take the vehicle
to your dealer service. Do not start the engine!
If it’s impossible to bring the vehicle to your dealer before starting
the engine, perform the service outlined on page 91, and take the
vehicle to your dealer at the first opportunity.

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. Before shifting into reverse, always check
for obstacles or people behind the vehicle and follow the reverse
operation procedures outlined in this manual. Always back slowly.

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. Engage the park brake.
3. Turn the engine off.
4. Block the rear wheels on the downhill side.

WARNING
A rolling vehicle can cause property damage and serious injury.
Always engage the park 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.
Operating the vehicle while the park brake is engaged could
cause loss of control and result in serious injury or death. Always
disengage the park brake before operating the vehicle.

Driving Safely

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:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO.
Always load the cargo box with the load as far forward and as low
as possible.
When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions.
Always operate the vehicle with extreme care when hauling or
towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads
can create unstable operating conditions, which could result in
loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED
LOADS. When handling off-centered loads that cannot be
centered, securely fasten the load and operate with extra caution.
Always attach the tow load to the hitch point designated for your
vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle. Avoid terrain or situations that may require
backing downhill.
USE EXTREME CAUTION when operating with loads that extend
over the rack sides. Stability and maneuverability may be
adversely affected, causing the vehicle to overturn.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass surface. Vehicle speed should
never exceed 5 mph (8 kph) when towing loads in rough terrain,
while cornering, or while ascending or descending a hill.

OPERATION
Driving Safely
Hauling Cargo
The RANGER has been designed to carry or tow specific capacities.
Always read and understand the load distribution warnings listed on
the warning labels. Never exceed the following capacities.
Maximum Capacities
(Level Ground)

Cargo Box

RANGER 4X4 XP

1500 lbs. (681 kg)

1000 lbs. (454 kg)

RANGER 6X6 EFI

1750 lbs. (794 kg)

1250 lbs. (567 kg)

WARNING
Driving with passengers in
the cargo box can result
in severe injury or death.
Never allow passengers
to ride in the cargo box.
Passengers must
always ride in the cab
with seat belts
fastened securely.

Driving Safely

OPERATION

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. Do
not attempt to dump or
unload the vehicle while
parked on an incline.
2. Engage the park brake.
3. Dismount the vehicle.
4. Ensure that the cargo is
positioned evenly or
toward the front of the
cargo box.
1
5. Release the tailgate by
pulling up on the tailgate latch.
6. Stand clear and pull up on the cargo box release lever (1).
7. Lift the front of the cargo box to dump the cargo.
8. Lower the cargo box and push down securely to latch.

WARNING
If the weight distribution on the box is located toward the rear of
the box when the release lever is pulled forward, the box may
dump unexpectedly and cause serious injury to the operator or
bystanders.
Never operate the dump lever without ensuring that the load is
positioned evenly or at the front of the box.

OPERATION
Driving Safely
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. See page 45. Towing a trailer increases braking
distance.
Do not tow more than the recommended weight for the vehicle.
See the towing capacity chart below and the specifications charts
beginning on page 100.
Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location or you may lose control of the vehicle.
Never tow a trailer on a grade steeper than 15°.

Maximum Towing Capacities (Level Ground)
Total Towed
Total Towed
Load Weight Load Weight
(level ground) (15° grade)

Total Hitch
Vertical
Weight

Maximum
Towing
Speed

RANGER

1500 lbs.
(681 kg)

850 lbs.
(386 kg)

150 lbs.
(68.1 kg)

10 mph
(16 kph)

RANGER

1750 lbs.
(794 kg)

1000 lbs.
(454 kg)

150 lbs.
(68.1 kg)

10 mph
(16 kph)

4x4 XP

6X6 EFI

Belt Life
To extend belt life, use the lowest gear possible when hauling or
towing heavy cargo.

Driving Safely

OPERATION

Parking the RANGER

WARNING
A rolling vehicle can cause property damage and serious injury.
Always engage the park brake after stopping the engine.

1.
2.
3.
4.

Stop the vehicle on a level surface.
Turn the engine off.
Engage the park brake.
Remove the ignition switch key to prevent unauthorized use.

WARNING
Gasoline is extremely flammable and can be explosive under
certain conditions. When parking inside a garage or other
structure, be sure that the structure is well ventilated and that the
vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.

OPERATION

Differential Lock (4X4)

The 4X4 rear axle is equipped with a lockable
differential that allows the operator to choose
between an open differential or a closed
differential. It’s beneficial to lock the
differential in low traction situations.
Move the AWD/Differential Lock rocker switch to
the center position (A) to lock the differential and
return to 2WD. Press the bottom of the switch (B)
to unlock the differential and return to 1WD.

AWD

A
B

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.

All Wheel Drive (AWD)

OPERATION

1
The illuminated amber AWD switch (1)
indicates that the vehicle is in AWD.
When the AWD switch is on, the front
wheels will automatically engage any time
the rear wheels lose traction. When the
rear wheels regain traction, the front
wheels will automatically disengage.
There is no limit to the length of time the
vehicle may remain in AWD.
When the RANGER 6X6 AWD switch is
off, the vehicle is in two-wheel drive at all
times.
When the RANGER 4X4 AWD switch is off, the vehicle is in
one-wheel drive at all times. See page 50 for 4X4 two-wheel
drive/differential lock operation.
The AWD switch may be turned on or off while the vehicle is moving.
If the switch is turned off while the front hubs are driving, they will not
release until the rear wheels regain traction.

CAUTION
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.

Disengaging AWD

Under certain conditions, it may be possible for the front gearcase to
remain locked unnecessarily. This condition causes increased steering
effort and some vehicle speed restriction.
Take the following steps to disengage the AWD system:
1. Stop the vehicle.
2. Shift to reverse and back up a minimum of 10 feet.
3. Stop completely.
4. Shift into low gear and drive forward.
If the front gearcase remains locked after following these instructions,
return the vehicle to your dealer for service.

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.
Federal law requires that this spark arrestor be installed and functional
when the vehicle is operated on public lands.
Operation of off--road vehicles on public lands in the U.S.A. is
regulated by 43 CFR 8343. Violations are subject to monetary
penalties. Federal regulations can be viewed online at
www.gpoaccess.gov/ecfr/.

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
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI
components are set at the factory for optimal performance and are not
adjustable.
Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed by an
authorized Polaris dealer.
Emissions labels are located on either the recoil cover, the stator
housing or the left side of the engine near the clutch cover.

Electromagnetic Interference
This spark ignition system complies with Canadian ICES--002.
This vehicle complies with European directives 97/24/EC and
89/336/EEC.

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.
Record maintenance and service in the Maintenance Log beginning on
page 116.
NOTE:

Service and adjustments are important for proper vehicle
operation. If you’re not familiar with safe service and
adjustment procedures, have a qualified dealer perform
these operations.

Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
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 or see your dealer.

MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Maintenance Chart Key
"

E
J

Perform these procedures more frequently for vehicles subjected to
severe use.
Emission Control System Service - 4 Cycle (California)
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.
Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.
Item

Maintenance Interval

(whichever comes first)
Hours Calendar
Miles
(Km)

Remarks

J Steering

Pre-Ride

" Front suspension

Pre-Ride

" Rear suspension

Pre-Ride

" Brake fluid level

Pre-Ride

" Brake pedal travel

Pre-Ride

Brake systems

Pre-Ride

Wheels/fasteners

Pre-Ride

Frame fasteners

Pre-Ride

" Engine oil level

Pre-Ride

" Air filter, pre-filter

Daily

Inspect; clean often

" Air box sediment

Daily

Drain deposits when visible

Daily

Check level daily, change
coolant every 2 years

Daily

Check operation; apply
dielectric grease if replacing

Weekly

Inspect; replace as needed

10 H

Monthly

Inspect periodically

20 H

Monthly

Check terminals; clean; test

" Front gearcase oil

25 H

Monthly

Inspect level; change yearly

" Middle gearcase

25 H

Monthly

Inspect level; change yearly

" Rear gearcase oil

25 H

Monthly

Inspect level; change yearly

" Transmission oil

25 H

Monthly

Inspect level; change yearly

Tires

E tube
Coolant
(if applicable)

Headlamp/tail
lamp
" Air filter,

E main element
" Brake pad wear
J

Battery
(if equipped)

oil (if equipped)
(if equipped)

Make adjustments
j
as needed See Pre
ed.
Pre-Ride
Ride Checklist
on page 34.

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service - 4 Cycle (California)
J Have an authorized Polaris dealer perform these services.
"

MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item

" Engine breather

Maintenance Interval

(whichever comes first)
Hours Calendar
Miles
(Km)

Remarks

25 H

Monthly

Inspect; replace if necessary

25 H

Perform a break-in oil
change at one month

50 H

Lubricate all fittings, pivots,
cables, etc.

50 H

Inspect, lubricate, adjust

J Steering

50 H

Lubricate

" Front suspension

50 H

Lubricate

" Rear suspension

50 H

Lubricate

J Throttle Cable/

50 H

Inspect; adjust; lubricate;
replace if necessary

50 H

Inspect ducts for proper
sealing/air leaks

Drive belt

50 H

Inspect; adjust; replace as
needed

Cooling system
(if applicable)

50 H

Inspect coolant strength
seasonally; pressure test
system yearly

" Engine oil change

100 H

Perform a break-in oil
change at 25 hours/one
month

" Oil filter change

100 H

Replace with oil change

E filter (if equipped)
" Engine oil change
(break-in)
" General

lubrication
Shift Linkage

E ETC Switch
E Throttle body air
intake ducts/
flange

" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service - 4 Cycle (California)
J Have an authorized Polaris dealer perform these services.

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

12 M

J Clutches (drive

100 H

12 M

Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Inspect; clean; replace worn
parts

J Front wheel

100 H

12 M

Inspect; replace as needed

J Brake fluid

200 H

24 M

Change every two years

300 H

36 M

Clean out

(if applicable)
(if applicable)

Exhaust muffler/
pipe

and driven)
bearings

Spark arrestor

Check for leaks at tank cap,
lines, fuel valve, filter, pump,
throttle body; replace lines
every two years
Replace yearly

Idle speed

Adjust as needed

J Toe adjustment

Inspect periodically; adjust
when parts are replaced

" Auxiliary brake (if
J equipped)

Inspect daily; adjust as
needed

Headlight aim

Adjust as needed

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service - 4 Cycle (California)
J Have an authorized Polaris dealer perform these services.
"

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
L Polaris Premium all Season Grease or grease conforming to NLGI
No. 2, such as Conoco Superlube M or Mobilegrease Special
F
Use Polaris Premium U-Joint Lube every 500 miles, before long
periods of storage, or after pressure washing or submerging.
"

Item

Lube

Method

Engine Oil

Polaris Premium 4
Synthetic 0W40

Add to proper level on dipstick.

Brake Fluid

DOT 3 or DOT 4

Maintain level between fill lines. See
page 82.

Main Gearcase Oil
(Transmission)

Premium AGL Synthetic Gearcase Lube

See page 64.

Front Gearcase Oil

Premium Demand
Drive Hub Fluid

See page 66.

Middle Gearcase Oil
(6X6 only)

Premium ATV Angle
Drive Fluid

See page 67.

Rear Gearcase Oil

Premium ATV Angle
Drive Fluid

See page 68.

(1) Prop Shaft U-joints

FGrease

Locate fittings and grease

Front Prop Shaft Yoke

FGrease

Locate fittings and grease
(3 pumps maximum)

(2) Ball Joint

"LGrease

Locate fitting (back side of struts),
grease with grease gun.

(3) Swing Arm
Bushings

LGrease

Locate fittings on swing arm and
grease with grease gun.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

6X6

(1)
4X4
6X6

6X6

4X4
6X6

(2)

6X6

(3)

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. See page 99 for the part
numbers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. Its
exceptional frictional properties result in more efficient operation, more
power output and lower fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified “SH” oil is allowable as long as
it’s 0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.

CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 All Season synthetic oil or API certified “SH” oil,
0W-40. Never substitute or mix oil brands. Use only 0W-40.

WARNING
Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine
seizure, accident, and injury. Always perform the maintenance
procedures as outlined in the Periodic Maintenance Chart.

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
The oil dipstick and fill tube (1) is located on the engine.
1. Position the vehicle on a level surface.
2. Apply the brakes. Start the
engine and let it idle for 20-30
seconds, then stop the engine.

3. Lift the lever lock (2) to remove
the dipstick. Wipe it dry with a
clean cloth.
4. Reinstall the dipstick completely,
but do not lock it. The dipstick
must be screwed completely in to
keep the angle and depth of the
2
stick consistent.
5. Remove the dipstick
and check the oil level.
Maintain the oil level
in the safe range (3).
Do not overfill.
NOTE:

Due to the dipstick entry
angle into the
crankcase, the oil level
will read higher on the
bottom side of the
dipstick. Always read
the level on the upper
surface (4) of the dipstick.

ADD 8 OZ

SAFE

6. After reinstalling the dipstick, be
sure to seat the lever lock.

MAINTENANCE AND LUBRICATION
Engine Oil

Oil and Filter Change

CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to
come into contact with skin.

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 53. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level surface.
2. Run the engine for two to three minutes until warm. Stop the
engine.
3. Clean the area around the drain plug.
4. Place a drain pan beneath engine crankcase and remove the drain
plug.
5. Allow the oil to drain completely.
6. Reinstall the sealing washer on the drain plug.
NOTE:

The sealing surfaces on drain plug and crankcase should be
clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).
8. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter counterclockwise to remove.
9. Using a clean dry cloth, clean the filter sealing surface on the
crankcase.
10. Lubricate the o-ring on the new filter with a film of fresh engine
oil. Check to make sure the o-ring is in good condition.
11. Install the new filter and turn by hand until the filter gasket
contacts the sealing surface, then turn and additional 1/2 turn.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change
12. Remove the dipstick and fill the sump with two quarts (1.9 l) of
recommended oil.
13. Shift the transmission to neutral.
14. Engage the park brake.
15. Apply the brakes. Start the engine. Allow it to idle for one to two
minutes.
16. Stop the engine. Inspect for leaks.
17. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.
18. Dispose of used filter and oil properly.

Gearcases

Gearcase Specification Chart
Gearcase

Lubricant

Capacity

Fill Plug
Torque

Drain Plug
Torque

Main Gearcase
(Transmission)

Premium AGL
Synthetic Gearcase
Lube

15.2 oz.
(450 ml)

14 ft. lbs.
(19.4 Nm)

Front Gearcase

Premium Demand
Drive Hub Fluid

5 oz.
(150 ml)

8-10 ft. lbs.
(11-13.6 Nm)

11 ft. lbs.
(15 Nm)

Middle Gearcase
(6X6)

Premium ATV Angle
Drive Fluid

6.75 oz.
(200 ml)

14 ft. lbs.
(19.4 Nm)

Rear Gearcase
(4X4)

Premium ATV Angle
Drive Fluid

18 oz.
(532 ml)

40-50 ft. lbs.
(54-68 Nm)

30-45 in. lbs.
(3-5 Nm)

Rear Gearcase
(6X6)

Premium ATV Angle
Drive Fluid

10 oz.
(300 ml)

14 ft. lbs.
(19.4 Nm)

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.
The fill plug (1) is located at the rear of
the vehicle.
Refer to the Gearcase Specifications
Chart on page 63 for recommended
lubricants, capacities and torque
specifications. See page 99 for the part
numbers of Polaris products.
Oil Check
1
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Check the oil level.
4. Add the recommended oil as needed.
5. Reinstall the fill plug. Torque to specification.

MAINTENANCE AND LUBRICATION

Gearcases

Transmission (Main Gearcase)
Oil Change
The drain plug (2) is located on the
bottom of the transmission. Access the
drain plug through the drain hole in the
skid plate.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
Remove the drain plug. Drain the oil.
Dispose of used oil properly.
3. Wipe the magnetic end of the drain
plug clean to remove accumulated
metallic filings.
4. After the oil has drained completely, install a
new sealing washer.
5. Reinstall the drain plug. Torque to specification.
6. Add the recommended oil as needed. Do not overfill.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks.

MAINTENANCE AND LUBRICATION
Gearcases

Front Gearcase
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.
The front gearcase fill plug (1) is located on the right side of the front
gearcase.
Refer to the Gearcase Specifications Chart on page 63 for
recommended lubricants, capacities and torque specifications. See
page 99 for the part numbers of Polaris products.
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
oil level.
3. Add the recommended oil as
needed.
4. Reinstall the fill plug. Torque to
specification.

Oil Change
1. Support the vehicle securely with a jackstand.
2. Remove the front tire on the driver’s side.
3. Remove the fill plug.
4. Place a drain pan under the drain plug (2) on the bottom right-hand
side.
5. Remove the drain plug. Drain the oil. Discard used oil properly.
6. Clean the drain plug. Reinstall the drain plug. Torque to
specification.
7. Add the recommended oil.
8. Reinstall the fill plug. Torque to specification.
9. Check for leaks.

MAINTENANCE AND LUBRICATION

Gearcases

Middle Gearcase (RANGER 6X6)
Always check and change the middle 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.
Refer to the Gearcase Specifications Chart on page 63 for
recommended lubricants, capacities and torque specifications. See page
99 for the part numbers of Polaris products.
The middle gearcase fill plug (1) is located on the side of the gearcase.
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check
the oil level.
3. Add the recommended oil as
needed.
4. Reinstall the fill plug. Torque to
specification.
1
Oil Change
2
1. Remove the fill plug.
2. Remove the drain plug (2) from
the bottom of the gearcase. Drain the oil into a drain pan. Discard
used oil properly.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.

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.
Refer to the Gearcase Specifications Chart on page 63 for
recommended lubricants, capacities and torque specifications. See
page 99 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 (6X6)
The easiest way to check for adequate oil in the 6X6 is to drain and
refill the gearcase to capacity (see page 63). Perform the oil change as
outlined on page 69.
Oil Check (4X4)
Maintain the oil level 3/4 of an inch
(19 mm) below the bottom thread of
the fill plug hole. Use a light colored
non-absorbent measuring instrument
(such as a white cable tie) to measure
the depth.
1. Position the vehicle on a
level surface.
2. Remove the fill plug. Check
the oil level.
3. Add the recommended
1
oil as needed.
4. Reinstall the fill plug.
Torque to specification.

6X6

4X4

MAINTENANCE AND LUBRICATION

Gearcases

Rear Gearcase
Oil Change
1. Remove the fill plug.
2. Place a drain pan under the drain plug (2). Remove the drain plug.
3. Drain the oil. Dispose of used oil properly.
4. Clean the drain plug. Reinstall the drain plug. Torque to
specification.
5. Add the recommended oil.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.

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 100.

Spark Plug Gap/Torque
Model

Electrode Gap

New Plug Torque

Used Plug Torque

RANGER
4X4 XP

.035″ (.9 mm)

18 ft. lbs.
(24 Nm)

RANGER
6X6 EFI

.035″ (.9 mm)

18 ft. lbs.
(24 Nm)

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.

WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.

1. Normal
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE:

The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect throttle body adjustments.

MAINTENANCE AND LUBRICATION

Spark Plugs

2. Wet Fouled
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended injection oil or incorrect throttle body
adjustments.

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.
2. Remove the spark plug cap. Using the spark plug wrench provided
in the tool kit, remove the plug by rotating it counterclockwise.
3. Reverse the procedure for spark plug installation. Torque to
specification. See page 70.

MAINTENANCE AND LUBRICATION
Cooling System
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. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
NOTE:

Some coolant level drop on new vehicles is normal as the
system is purging itself of trapped air. Observe coolant
levels and maintain as recommended by adding coolant to
the overflow bottle.

Adding or Changing Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and
a fresh mixture of antifreeze and water added. Polaris recommends the
use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of
high quality aluminum compatible anti-freeze/coolant and distilled
water. Polaris Premium 60/40 is already premixed and ready to use.
Do not dilute with water. See page 99 for the part numbers of Polaris
products.
NOTE:

Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.

Any time the cooling system has been drained for maintenance or
repair, replace the coolant. If the recovery bottle has run dry, the level
in the radiator should be inspected. Add coolant as needed.

MAINTENANCE AND LUBRICATION

Cooling System

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.

CAUTION
Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator’s effectiveness. Exercise
caution if a high-pressure system is used for washing the vehicle.

Coolant Level

Always check and change the coolant at
the intervals outlined in the Periodic
Maintenance Chart beginning on page 53.
1
Maintain the coolant level between the
minimum and maximum marks on the
bottle (when the fluid is cool). The
overflow bottle (1) is located in front of
the right front wheel.
1. Position the vehicle on level ground.
2. View the coolant level in the overflow bottle.
3. If the coolant level is below the safe operating range, lift the hood
and locate the overflow bottle lid. Remove the lid and use a funnel
to add coolant through the filler opening. Reinstall the cap.
NOTE:

If coolant must be added often, or if the overflow bottle runs
completely dry, there may be a leak in the system. Have the
cooling system inspected by your Polaris dealer.

MAINTENANCE AND LUBRICATION
Cooling System

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. Use a funnel and slowly add
coolant as needed.
NOTE:

NOTE:

This procedure is
required only if the
cooling system has
been drained for
maintenance and/or
repair. But if the
overflow bottle has
run dry, the level in
the radiator should
also be inspected.

Use of a non-standard pressure cap will not allow the
recovery system to function properly. See your dealer for
the correct replacement part.

MAINTENANCE AND LUBRICATION

Polaris Variable Transmission (PVT) System

Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).

When To Use Low Range vs. High Range
Following is a guideline for when to use low range and high range.
Low Range
S When basic operation is at speeds less than 7 MPH (11 KPH)
S For heavy pulling
S When operating in rough terrain (swamps, mountains, etc.) at low
ground speeds
High Range
S When basic operation is at speeds greater than 7 MPH (11 KPH)
S When operating at high ground speeds

MAINTENANCE AND LUBRICATION
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.
The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.

MAINTENANCE AND LUBRICATION

PVT System
PVT Drying

There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating.
1. Loosen the bottom screws that secure the clutch cover.
2. Allow the water to drain.
3. Tighten the screws.
4. Apply the brakes. Start the engine.
5. Engage the park brake.
6. Shift the transmission to neutral.
7. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open
for more than 10 seconds.
8. Allow the engine RPM to settle to idle speed. Apply the service
brakes. Release the park brake and shift the transmission to the
lowest available range.
9. Test for belt slippage. If the belt slips, repeat the process.
10. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE AND LUBRICATION
Filter Systems
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.
NOTE:

Apply a small amount of
general purpose grease to
the sealing edges of the
filter before installing.

5. Inspect the air box for oil or water deposits. If present, drain them
into a suitable container.
NOTE:

Service the air filter more frequently if the vehicle is operated
in wet conditions or at high throttle openings for extended
periods.

Fuel Filter
Your Polaris vehicle is equipped with an in-line fuel filter. Have your
dealer replace it after every 100 hours of operation. Do not attempt to
clean the fuel filter.

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.
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.
Never go under the vehicle while it’s inclined.

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. Shift the transmission to neutral.
Apply the brakes. Start the
engine.
3. Purge accumulated carbon from
the system by momentarily
2 1
revving the engine several times.
4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap
on the pipe around the clean-out plugs while revving the engine
several more times.
5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Engage the park
brake. Block the wheels. Make sure the transmission is in neutral
and repeat steps 3 and 4 until no more particles are expelled when
the engine is revved.
6. Stop the engine. Allow the arrestor to cool.
7. Reinstall the arrestor plugs and remove the outlet cover or plug.

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.
Always check the pedal for free movement and return before
starting the engine and occasionally during operation.

Throttle Freeplay

If the throttle pedal (1) has excessive play
due to cable stretch or misadjustment, it
will cause a delay in throttle response,
especially at low engine speed. The throttle
may also not open fully. If the throttle
pedal has no freeplay, the throttle may be
hard to control, and the idle speed may be
erratic.
Check the throttle pedal freeplay at the
intervals outlined in the Periodic
Maintenance Chart beginning on page 53.
Adjust the freeplay if necessary.

Throttle Freeplay Inspection

1. Engage the park brake (2). Shift the transmission to neutral.
2. Apply the brakes. Start the engine. Allow it to warm 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
(1.6-3.2 mm).

MAINTENANCE AND LUBRICATION

Throttle System

Throttle Freeplay Adjustment

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).
2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved.
NOTE:

While adjusting, flip the throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the midpoint of adjuster.
1

Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your Polaris dealer for adjustment.

MAINTENANCE AND LUBRICATION
Brakes

The front and rear brakes are hydraulic disc type brakes and are
activated by the brake pedal. See page 32.

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. The brake fluid should also
be changed if it becomes contaminated, if the fluid level is below the
minimum, or if the type and brand of the fluid in the reservoir are
unknown.
1
1. Position the vehicle on a level
surface.
2. View the brake fluid level at the
reservoir (1) under the hood. The
level should be between the upper
(MAX) and lower (MIN) level
lines.
3. If the fluid level is lower than the
lower level line, add brake fluid to
the upper (MAX) line.
4. Apply the brake forcefully for a
few seconds and check for fluid
leakage around the fittings.

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.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury.

Brakes

MAINTENANCE AND LUBRICATION

Brake Inspection

5. Check the brake system for fluid
leaks.
6. Check the brake pedal for excessive
travel or a spongy feel.
7. Check the friction pads for wear,
damage and looseness.
8. Inspect the brake disc spline and
pad wear surface for excessive wear.
9. Change pads when worn to 3/64″
(1 mm).

3/64″ (1 mm)

Park Brake Inspection

1. Slowly push the park brake pedal
down with your foot.
2. After 8 to 12 clicks of pedal
travel, check the vehicle for
movement. The vehicle should
not roll while parked. If the
vehicle moves, adjustment is
necessary.

Park Brake Adjustment

1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Loosen or tighten the nuts on the
pedal end of the park brake cable as
needed.

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. If there is excessive freeplay or strange noises, or the steering feels
rough or “catchy,” have the steering system inspected by an
authorized Polaris dealer.

Suspension Adjustment (4X4)
The 4X4 rear suspension may be adjusted to provide a stiffer
suspension if necessary. The shocks are mounted to the inside
mounting holes (A) at the factory, but they may be relocated to the
outside mounting holes (B).
1. Remove the top shock mounting bolts (A).
2. Reposition the shocks to the outside mounting holes (B).
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).
B
A

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment
cam (C) either clockwise or counterclockwise to increase or decrease
spring tension.

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. If any
irregularities are found, have the seat belt system checked and/or
replaced by an authorized Polaris dealer.
The RANGER seat belt is adjustable and
should be adjusted for both the operator
and passengers before driving. Although
having the belt at 30° is typical for many
people, it will not accommodate all body
sizes and shapes. Make sure the seat belt
is adjusted to the lowest possible lap
position before riding.
1. To adjust, loosen the bolts (1).
2. Reposition both the buckle and
retractor. Tighten the bolts.
NOTE:

The center belt does not self
adjust. Before riding, pull on the
strap to secure the belt on the lap
of the center passenger.

WARNING
Failure to follow the age recommendations for this vehicle could
result in serious injury or death. No one under the age of 16 may
operate this vehicle. No one under the age of 5 may ride as a
passenger in this vehicle.

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 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. When replacing tires, always use original equipment
size and type.

Tire Tread Depth

Always replace tires when tread depth
is worn to 1/8″ (3 mm) or less.

1/8I (3 mm)

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they’ve
been loosened for maintenance service.

Location

Specification

Front Wheel Nuts

35 ft. lbs. (47 Nm)

Rear Wheel Nuts

35 ft. lbs. (47 Nm)

Front Spindle Nut

70 ft. lbs. (95 Nm)

Center and Rear Hub
Retaining Nuts

110 ft. lbs. (150 Nm)

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. Engage the park
brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the
frame.
4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Place the
transmission in gear.
2. Engage the park
brake.
3. Place the wheel in
the correct position
on the wheel hub. Be
sure the valve stem is
toward the outside and rotation
arrows on the tire point toward
forward rotation.
4. Attach the wheel nuts and washers
and finger tighten.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts to specification. See page 86.

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. Do not service
the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Open the hood.
2. Unplug the headlamp from the
wiring harness (1). Be sure to pull
on the connector, not on the wiring.
3. Turn the lamp counterclockwise to
remove it.
4. Install the new lamp.
NOTE:

Make sure the tab on the
lamp locates properly in the
housing.

5. Reinstall the harness assembly into
the headlight assembly.

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. 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 8″ (20.3 cm) below
the mark placed on the wall
in step 2.
1
NOTE:

Include the weight of a rider on
the seat while performing this step.

5. Adjust the beam to the desired position by turning the adjustment
screw (1).

Brake Lights
When the brake pedal is depressed, the console brake light comes on.
Check the brake light before each ride.
1. Turn the ignition switch to the ON position.
2. Depress the brake pedal. The brake light should come on after
about 10mm (0.4 in.) of pedal travel. If the light doesn’t come on,
check the bulb.

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. Install the new light and use a small flat head screwdriver to seat it
into place, 1/4 turn clockwise.
7. Snap the assembly back into the console panel and reconnect the
harness.
8. Close the hood.

Tool Kit

To help you perform routine maintenance, a tool kit is provided with
your vehicle. Items included in the kit are:
S A screwdriver
S An open-end wrench (8-10 mm)
S An open-end wrench (12-14 mm)
S A tire pressure gauge
S A spark plug wrench and handle
S A spanner wrench (for shock adjustment)
NOTE:

Additional tools will be necessary to perform routine
maintenance.

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 water below
the footrests.
2. Dry any water present in the air box.
NOTE:

Filter replacement is required if water is present.

3.
4.
5.
6.
7.

Thoroughly dry the air pre-cleaner located under the hood.
Remove the spark plugs.
Turn the engine over several times using the electric start.
Dry the spark plugs and reinstall, or replace with new plugs.
Attempt to start the engine. If necessary, repeat the drying
procedure.
8. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE:

If water has been ingested into the PVT follow the procedure
on page 77 for drying.

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. 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. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near
batteries. KEEP OUT OF REACH OF CHILDREN.

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. When
removing the battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always connect the
negative (black) cable last.

Battery Removal

1. Open the hood.
2. Remove the battery vent
tube from the battery.
3. Disconnect the black
(negative) battery cable first.
4. Disconnect the red (positive)
battery cable next.
5. Lift the battery out of the
vehicle, being careful not to
tip it sideways and spill any
electrolyte.

CAUTION
If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to
the vehicle.

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. Verify that cables are properly routed.
NOTE:

When installing a new battery, make sure it’s fully charged
prior to its initial use. 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.

Battery Storage
When the vehicle is placed in storage for three months or more, the
battery should be removed, stored out of the sun in a cool, dry place
and tested monthly. Before reusing, take the battery to your dealer for
testing and recharging.

MAINTENANCE AND LUBRICATION
Cleaning and Storage
See page 99 for the part numbers of Polaris products.

Cleaning the RANGER
Keeping your RANGER clean will not only improve its appearance but
it can also extend the life of various components. With a few
precautions, your RANGER can be cleaned much like an automobile.

Washing the RANGER
The best and safest way to clean your RANGER 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. Rinse
with water frequently and dry with a chamois to prevent water spots.
NOTE:

If warning and safety labels are damaged, contact your a
Polaris dealer for free replacement.

CAUTION
High water pressure may damage vehicle components. Polaris
recommends washing the vehicle by hand or with a garden hose
using mild soap.
Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Do not allow these types of products to
come into contact with the vehicle.

If a high pressure water system is used, exercise extreme caution to
avoid damaging wheel bearings, radiator, transmission seals, body
panels, brakes and warning labels. Grease all zerk fittings immediately
after washing, and allow the vehicle to run for a while to evaporate any
water that may have entered the engine or exhaust system.

Waxing the RANGER
Your RANGER can be waxed with any non-abrasive automotive paste
wax. Avoid the use of harsh cleaners since they can scratch the body
finish.

MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips

CAUTION
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 necessary repairs and then clean the vehicle thoroughly with
mild soap and warm water to remove all dirt and grime. Don’t use
harsh detergents or high pressure washers. Some detergents deteriorate
rubber parts. Use dish soap type cleaners only. High pressure washers
may force water past seals.
Stabilize the Fuel
Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris
Fuel Stabilizer. Follow the instructions on the container for the
recommended amount. (Carbon clean will also reduce the possibility of
bacterial growth in the fuel system.) Allow 15-20 minutes of operation
for the stabilizer to disperse through the fuel in the tank.
Oil and Filter
Warm the engine and change the oil and filter.
Air Filter / Air Box / Breather Filter
Inspect and clean or replace the pre-cleaner and air filter. Clean the air
box and drain the sediment tube.
Fluid Levels
Inspect the following fluid levels and change if necessary: front and
rear gearcases; transmission and brake fluid (change every two years or
as required if fluid looks dark or contaminated).
Inspect and Lubricate
Inspect all cables and lubricate. Follow lubrication guidelines in the
Maintenance Section of the service or owner’s manual to completely
grease and lubricate the entire vehicle with Polaris Premium All
Season Grease.

MAINTENANCE AND LUBRICATION

Cleaning and Storage
Storage Tips

Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean, following the
instructions on the can. Run the engine for several minutes so the
Carbon Clean reaches the injectors. Turn the engine off.
2. Remove the spark plugs and add 2-3 tablespoons of Premium 4
Synthetic 0W40 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.
NOTE:

Do this carefully! If you miss the plug holes, oil will drain from
the spark plug cavities into the hole at the front of the cylinder
head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 70.
4. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protective
film of fresh oil.
6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
Battery Maintenance
Remove the battery and recharge it fully. Store the battery in a cool,
dry place.
Engine Anti-Freeze
Test engine coolant strength and change if necessary. Coolant should
be replaced every two years.
Storage Area/Covers
Be sure the storage area is well ventilated, and cover the machine with a
genuine Polaris cover.
NOTE:

Do not use plastic or coated materials. They do not allow
enough ventilation to prevent condensation, and may promote
corrosion and oxidation.

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 34.
NOTE:

Tightness of the bolts, nuts and other fasteners should be
checked by an authorized Polaris dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 53.

WARNING
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness or death. Never run an engine in an
enclosed area.

Transporting the RANGER

Follow these procedures when transporting the vehicle.
1. Turn off the engine and remove the key to prevent loss during
transporting.
2. Place the transmission in gear. Engage the park brake.
3. Be sure the fuel cap, oil cap and seat are installed securely.
4. Always tie the frame of the RANGER to the transporting unit
securely with suitable straps or rope. Do not attach tie straps to the
front A-arm bolt pockets.

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.)
Pump for Gallon Jug
Premium Demand Drive Hub Fluid (8 oz.)
Premium Demand Drive Hub Fluid (2.5 gal.)

2871322
2871423
2871460
2871515
2871551
2871312
2871329
2872073
2872348

Grease / Specialized Lubricants
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Starter Drive Grease
Premium U-Joint Lube (3 oz.)
Premium U-Joint Lube (14 oz.)
Grease Gun Kit
Dielectric Grease (Nyogelt)
Chain Lube (6.25 oz. aerosol)
Chain Lube (16 oz. aerosol)

2871323
2871534

Coolant
60/40 Coolant (gal.)
60/40 Coolant (qt.)

2872889
2871326
2870652
2870990
2872893
2871956

Additives / Miscellaneous
Brake and Clutch Cleaner
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT3 Brake Fluid
Engine Degreaser
LOCTITE 565 Thread Sealant

SPECIFICATIONS
RANGER 4X4 XP
Gross Vehicle Weight
Dry Weight
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Towing Capacity
Hitch Tongue Capacity
Max. Cargo Box Load
Overall Length
Overall Width (box)
Overall Width (tires)
Overall Height
Wheelbase
Cargo Box
(L x W x H)
Ground Clearance
Min. Turning Radius
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Front Suspension
Rear Suspension

100

2750 lbs. (1247 kg)
1185 lbs. (537 kg)
8 gal. (30.3 l)
2 qts. (2.1 l)
3.25 qts. (3 l)
1500 lbs. (681 kg)
150 lbs. (68 kg)
1000 lbs. (454 kg)
113 in. (282 cm)
60 in. (152.4 cm)
58 in. (147.3 cm)
75 in. (190.5 cm)
76 in. (193 cm)
58 x 42 x 10 in.
(147 x 106.7 x 25.4 cm)
11.5 in. (29 cm)
132 in. (335.3 cm)
4 valve 4 stroke twin cylinder with
counter balance
683 cc
80 x 68
500 W @ 3000 RPM
9.40:1
Electric
Electronic Fuel Injection
ECU
RC7YC / .035 in. (0.9 mm)
MacPherson strut
w/8 in. (20.3 cm) of travel
Independent
w/9.0 in. (22.9 cm) of travel

SPECIFICATIONS
RANGER 4X4 XP
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, Park
Hood Headlight
Taillights
Brake Light
Indicator Light
NOTE:

Pressurized Wet Sump
0W/40
PVT, 4-wheel independent shaft,
lockable differential
Single Lever (H/L/N/R)
8.71:1
5.94:1
3.14:1
3.83:1
3.70:1
26 x 8 - 12
26 x 11 - 12
8-12 psi
8-12 psi
Foot Activated,
4 wheel hydraulic disc
Foot activated, mechanical
2 dual beam, 35W, quartz/halogen
2 single beam, 5W
2 single beam, 5W
1.0 W

See your Polaris dealer for clutching specifications.

101

SPECIFICATIONS
RANGER 6X6 EFI
Gross Vehicle Weight
Dry Weight
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Towing Capacity
Max. Cargo Box Load
Overall Length
Overall Width (box)
Overall Width (tires)
Overall Height
Wheelbase
Ground Clearance
Min. Turning Radius
Cargo Box (L x W x H)
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Lubrication System
Engine Oil

102

2900 lbs. (1317 kg)
1410 lbs. (640 kg)
8 gal. (30.3 l)
2 qts. (2.1 l)
3.25 qts. (3 l)
1750 lbs. (794 kg)
1250 lbs. (567 kg)
120 in. (304.8 cm)
60 in. (152.4 cm)
58 in. (147.3 cm)
75 in. (190.5 cm)
90 in. (228.6 cm)
7.2 in. (18 cm)
180 in. (457.2 cm)
58 x 48 x 10 in.
(147 x 122 x 25.4 cm)
4 valve 4 stroke twin cylinder
with counter balance
683 cc
80 x 68
500 W @ 3000 RPM
9.40:1
Electric
Electronic Fuel Injection
ECU
RC7YC / .035 in. (0.9 mm)
Pressurized Wet Sump
0W/40

SPECIFICATIONS
RANGER 6X6 EFI
Front Suspension
Center Suspension
Rear Suspension
Driving System Type
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front:
Drive Ratio - Final
Tire Size - Front
Tire Size - Center/Rear
Tire Pressure - Front
Tire Pressure - Center/Rear
Brakes, Front/Rear
Brake, Parking
Hood Headlight
Taillights
Brake Light
Indicator Light
NOTE:

MacPherson strut
w/6.25 in. (15.9 cm) of travel
Independent
w/5.25 in. (13.3 cm) of travel
Swing arm w/dual shocks
w/6.25 in. (15.9 cm) of travel
PVT
Single Lever (console)
8.71:1
5.9:1
3.14:1
3.83:1
3.70:1
25 x 10 - 12
25 x 11 - 12
8-12 psi
8-12 psi
Foot Activated,
4 wheel hydraulic disc
Foot activated, mechanical
2 dual beam, 35W, quartz/halogen
2 single beam, 5W
2 single beam, 5W
1.0 W

See your Polaris dealer for clutching specifications.

103

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

Low battery voltage

Recharge battery to 12.5 VDC

Loose battery connections

Check all connections and tighten

Loose solenoid connections

Check all connections and tighten

Loose electronic control box connections

Inspect, clean, reinstall connectors

Engine Turns Over, Fails to Start
Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel filter

Inspect and clean or replace

Water is present in fuel

Drain the fuel system and refuel

Old or non-recommended fuel

Replace with new fuel

Fouled or defective spark plug(s)

Inspect plug(s), replace if necessary

No spark to spark plug

Inspect plug(s), replace if necessary

Crankcase filled with water or fuel

Immediately see your Polaris dealer

Clogged fuel filter

Replace the filter

Low battery voltage

Recharge battery to 12.5 VDC

Mechanical failure

See your Polaris dealer

Engine Pings or Knocks
Possible Cause

Solution

Poor quality or low octane fuel

Replace with recommended fuel

Incorrect ignition timing

See your Polaris dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

104

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 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 connections and tighten

Water present in fuel

Replace with new fuel

Low battery voltage

Recharge battery to 12.5 VDC

Kinked or plugged fuel vent line

Inspect and replace

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause

Solution

Low or contaminated fuel

Add or change fuel, clean the fuel system

Low octane fuel

Replace with recommended fuel

Clogged fuel filter

Replace filter

Possible Rich Fuel Mixture Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

105

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

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 connections and tighten

Low battery voltage

Recharge battery to 12.5 VDC

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

Other mechanical failure

See your Polaris dealer

Overheated engine

Clean radiator screen and core if equipped
Clean engine exterior
See your Polaris dealer

106

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.

REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in
ensuring trouble-free operation. Purchasing a machine in the crate or without
proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any vehicle that
has been altered structurally, neglected, improperly maintained, used for racing, or used
for purposes other than for which it was manufactured, or for any damages which occur
during trailer transit or as a result of unauthorized service or the use of unauthorized
parts. In addition, this warranty does not cover physical damage to paint or finish, stress
cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle caused by fire, explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the vehicle. The exclusive remedy for breach of this warranty
shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or
components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE
THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY
OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply
to you if inconsistent with controlling state law.

107

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.

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.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.

Lubricants
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.

SPARK ARRESTOR
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements
of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations.

108

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.
This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.

How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.

How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.

Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government
officials or military personnel on assignment outside of the country where the vehicle
was purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100

109

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.
The emissions warranty period for this vehicle begins on the date the vehicle is delivered
to the original retail purchaser and ends 30 months (2.5 years) after that date, or after
5000 km (3100 miles), whichever comes first.
This emission-related warranty covers components whose failure would increase an engine’s emissions, including electronic controls, fuel injection, exhaust-gas recirculation,
aftertreatment, or any other system utilized in this vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or the standard
warranty is the responsibility of the owner; including the parts, labor and other costs
associated with recommended maintenance.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option
of Polaris, repair or replacement of any defective materials, components or products.
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD
DESCRIBED HEREIN. POLARIS 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 if it is inconsistent
with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper
handling, maintenance or use. This limited warranty also does not cover any engine that
has been structurally altered, or any engine that has been used in racing competition. This
limited warranty also does not cover physical damage, corrosion or defects caused by
fire, explosions or other similar causes beyond the control of Polaris.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the Polaris Warranty Department at 1-763-417-8650.

110

WARRANTY
California Emission Control Warranty Statement
The Air Index of this Engine is 3
0
2
Most Clean

10
Least Clean

Note: The lower the Air Index, the less pollution.
This engine is certified to be emission compliant
for 1000 hours of use.

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 Large Spark Ignition Engine (herein “LSI engine”). “The California Air Resources Board has designated this engine for this vehicle as an LSI engine
which produces 25 and greater horsepower and the vehicle has a six (6) or four (4)-wheel
drive and/or a round steering wheel.” In California, this LSI engine must be designed,
built and equipped to meet the state’s stringent anti-smog standards. Polaris must warrant
the emission control system on your LSI engine for the period of time described below,
provided there has been no abuse, neglect or improper maintenance of your LSI engine.
Your emission control system includes parts such as the carburetor and the ignition system. Also included may be hoses, connectors and other emission-related assemblies.
Where a warrantable condition exists, POLARIS will repair your LSI engine at no cost to
you, including diagnosis, parts and labor.

Manufacturer’s Warranty Coverage:
LSI engines are warranted for two (2) years. If any emission related part on your LSI
engine is defective, the part will be repaired or replaced by POLARIS.

111

WARRANTY
California Emission Control Warranty Statement
Owner’s Warranty Responsibilities:
S As the LSI engine owner, you are responsible for the performance of the required
maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Owner’s Manual”). POLARIS recommends that you retain all receipts covering maintenance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of
receipts or for your failure to ensure the performance of all scheduled maintenance.
S As the LSI engine owner, you should, however, be aware that POLARIS may deny
you warranty coverage if your LSI engine or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
S You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists. The warranty repairs should be completed in a
reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the Polaris Warranty Department at 1-763-417-8650.

Limited Warranty
California Only
POLARIS warrants to the owner of the LSI engine installed in their Polaris vehicle that
the LSI engine (1) has been designed, built, and equipped at the time of manufacture so
as to conform with the applicable regulations of the California Air Resources Board and,
(2) is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated
below.

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.

What is Covered Under This Warranty

Repair and/or replacement of any warranted emission-related part will be performed at
no charge provided the work is performed at an authorized dealer. There will also be no
charge for any diagnostic labor performed at an authorized dealer, which leads to the
determination that a warranted emission-related part is defective.
Any warranted part which is not scheduled for replacement as required maintenance, or
which is scheduled only for regular inspection to the effect of “repair or replace as
necessary” shall be warranted for the warranty period. Any warranted part which is
scheduled for replacement as required maintenance shall be warranted for the period of
time up to the first scheduled replacement of that part. This warranty shall apply only
towards the repair, replacement, and/or adjustment of the component parts listed below.

112

WARRANTY
California Emission Control Warranty Statement
Emission-Related Parts Covered Under This Warranty

(1) Fuel Metering System
(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system).
(ii) Air/fuel ratio feedback and control system, if applicable.
(iii) Cold start enrichment system, if applicable.
(iv) Regulator assy (gaseous fuel, if applicable)
(2) Air Induction System
(i) Intake manifold, if applicable
(ii) Air filter
(3) Ignition System
(i) Spark plugs.
(ii) Magneto or electronic ignition system.
(iii) Spark advance/retard system, if applicable.
(4) Exhaust manifold, if applicable
(5) Miscellaneous Items Used in Above Systems
(i) Electronic controls, if applicable
(ii) Hoses, belts, connectors, and assemblies.
(iii) Filter lock assy (gaseous fuel, if applicable)
If an authorized dealer determines that other LSI engine components have been damaged
due to the failure of a warranted emission-related part during the warranty period, POLARIS will repair and/or replace the necessary components.

113

WARRANTY
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. This limited warranty also does not
apply to any emission-related part which malfunctions, fails, or is damaged due to failure
to follow the maintenance and operating instructions specified in the Owner’s Manual
including:
(a) Improper or inadequate maintenance of any warranted emission-related part
(b) Improper installation, adjustment, or repair of the LSI engine or any warranted emission-related part unless performed by an authorized dealer
(c) Failure to use recommended fuel as specified in the Owner’s Manual
(d) Repairs and diagnosis performed outside of an authorized dealer
(e) Use of parts which are not authorized by POLARIS

Maintenance Schedule

The LSI engine owner is responsible for having all scheduled inspection and
maintenance services performed at the intervals specified in the Owner’s Manual and to
retain records of these services as having been performed. These records should be
transferred to each subsequent owner of the LSI engine. POLARIS cannot deny a claim
solely because there are no records of scheduled maintenance, however, a warranty claim
may be denied if the failure to perform the scheduled maintenance and inspection
resulted in the failure of a warranted emission-related part. As a minimum, the LSI
engine owner is responsible for the scheduled inspection and maintenance described
below which are based on the procedures described in the Owner’s Manual.

114

WARRANTY
Maintenance Schedule Key
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
"

Item

Maintenance Interval

(whichever comes first)
Hours Calendar
Miles
(Km)

Remarks

" Air filter, pre-filter

Daily

Inspect; clean often

" Air box sediment

Daily

Drain deposits when visible

" Air filter,

Weekly

Inspect; replace as needed

25 H

Monthly

Inspect; replace if necessary

50 H

Inspect; adjust; lubricate; replace if necessary

E Throttle body air

50 H

Inspect ducts for proper
sealing/air leaks

J Valve clearance

100 H

12 M

Inspect; adjust

J Fuel system

100 H

12 M

J Spark plug

100 H

12 M

Check for leaks at tank cap,
lines, fuel valve, filter, pump,
throttle body; replace lines
every two years
Inspect; replace as needed

E tube

E main element
" Engine breather

E filter (if equipped)
J Throttle Cable/
E ETC Switch
intake ducts/
flange

E
E

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.

How to File a Warranty Claim/Where to Get Warranty Service

All repairs qualifying under this Limited Warranty must be performed by a dealer who
sold you the LSI engine or a dealer authorized by POLARIS. In the event that any
emission-related part is found to be defective during the warranty period, you must
notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of
the appropriate dealer where the warranty repair is to be performed.

115

MAINTENANCE LOG
Periodic Maintenance Record
Use the following chart to record periodic maintenance.
DATE

116

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

MAINTENANCE LOG
DATE

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

117

INDEX
A
Age Restrictions . . . . . . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . .
All Wheel Drive (AWD) . . . . . . . . . .
Auxiliary Outlet . . . . . . . . . . . . . . . .
AWD Switch . . . . . . . . . . . . . . . . . . .

E
5
78
51
26
31

B
Battery . . . . . . . . . . . . . . . . . . . . . 92-94
Battery Fluid . . . . . . . . . . . . . . . . . . . 93
Battery Installation . . . . . . . . . . . . . . 94
Battery Removal . . . . . . . . . . . . . . . . 93
Battery Storage . . . . . . . . . . . . . . . . . 94
Brake Fluid . . . . . . . . . . . . . . . . . . . . 82
Brake Inspection . . . . . . . . . . . . . . . . 83
Brake Lights . . . . . . . . . . . . . . . . . . . 89
Brake Pedal . . . . . . . . . . . . . . . . . . . . 32
Brakes . . . . . . . . . . . . . . . . . . . . . . 82-83
Braking . . . . . . . . . . . . . . . . . . . . . . . 36

C
Cleaning . . . . . . . . . . . . . . . . . . . . 95-97
Component Locations . . . . . . . . . . 23-25
Console . . . . . . . . . . . . . . . . . . . . . . . 29
Coolant . . . . . . . . . . . . . . . . . . . . . . . 72
Coolant Level . . . . . . . . . . . . . . . . . . 73
Cooling System . . . . . . . . . . . . . . 72-74
Cooling System Operation . . . . . . . . 72
Crankcase Emission Control System . 52

D
Decals and Locations . . . . . . . . . . 18-21
Differential Lock . . . . . . . . . . . . . . . . 50
Differential Lock Switch . . . . . . . . . . 31
Disengaging AWD . . . . . . . . . . . . . . 51
Driving Downhill . . . . . . . . . . . . . . . 40
Driving in Reverse . . . . . . . . . . . . . . 43
Driving On Slippery Surfaces . . . . . . 38
Driving Over Obstacles . . . . . . . . . . . 42
Driving Procedures . . . . . . . . . . . . . . 37
Driving Safely . . . . . . . . . . . . . . . . 37-49
Driving Through Water . . . . . . . . . . . 41
Driving Uphill . . . . . . . . . . . . . . . . . 39
Dumping the Cargo Box . . . . . . . . . . 47

118

Electromagnetic Interference . . . . . . . 52
Emission Control Systems . . . . . . . . 52
Emissions Warranty . . . . . . . . . . . . 110
Engine Oil . . . . . . . . . . . . . . . . . . . 60-63
Equipment Modifications . . . . . . . . . 10
Exhaust Emission Control System . . 52

F
Filter Systems . . . . . . . . . . . . . . . . . .
Front Gearcase . . . . . . . . . . . . . . . . .
Fuel Cap . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge . . . . . . . . . . . . . . . . . . . .
Fuel Safety . . . . . . . . . . . . . . . . . . . .

78
66
27
78
27
22

G
Gear Selector . . . . . . . . . . . . . . . . . . . 30
Gearcase Specification Chart . . . . . . . 63
Gearcases . . . . . . . . . . . . . . . . . . . 63-69

H
Hauling Cargo . . . . . . . . . . . . . . . . 45-46
Headlight Beam Adjustment . . . . . . . 89
High Range . . . . . . . . . . . . . . . . . . . . 75

I
Idle RPM . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . .
Indicator Lamp Replacement . . . . . .
Indicator Lights . . . . . . . . . . . . . . . . .

81
31
90
26

L
Light Switch . . . . . . . . . . . . . . . . . . . 31
Lights . . . . . . . . . . . . . . . . . . . . . . 88-90
Low Range . . . . . . . . . . . . . . . . . . . . 75
Lubrication Recommendations . . . 58-59

M
Main Gearcase . . . . . . . . . . . . . . . 64-65
Maintenance Chart . . . . . . . . . . . . 53-57
Maintenance Log . . . . . . . . . . . 116-117
Middle Gearcase . . . . . . . . . . . . . . . . 67

INDEX
N

Noise Emission Control System . . . . 52

Spark Plugs . . . . . . . . . . . . . . . . . . 70-71
Specifications . . . . . . . . . . . . . . 100-103
Starting the Engine . . . . . . . . . . . . . . 35
Steering Wheel Inspection . . . . . . . . 84
Stopping the Engine . . . . . . . . . . . . . 36
Storage . . . . . . . . . . . . . . . . . . . . . 95-97
Storage Tips . . . . . . . . . . . . . . . . . 96-97
Suspension Adjustment . . . . . . . . . . . 84
Switches . . . . . . . . . . . . . . . . . . . . . . 31

O
Oil and Filter Change . . . . . . . . . . 62-63
Oil Check . . . . . . . . . . . . . . . . . . . . . 61
Operator Safety . . . . . . . . . . . . . . . . 5-17

P
Park Brake Adjustment . . . . . . . . . . . 83
Park Brake Inspection . . . . . . . . . . . . 83
Park Brake Pedal . . . . . . . . . . . . . . . . 32
Park Brake Release . . . . . . . . . . . . . . 32
Parking on an Incline . . . . . . . . . . . . 44
Parking the RANGER . . . . . . . . . . . . 49
Periodic Maintenance Chart . . . . . 53-57
Polaris Products . . . . . . . . . . . . . . . . 99
Pre Ride Inspection . . . . . . . . . . . . . . 34
Premium 4 Synthetic Oil . . . . . . . . . . 60
PVT Drying . . . . . . . . . . . . . . . . . . . 77
PVT SYSTEM . . . . . . . . . . . . . . . . . 75
PVT System . . . . . . . . . . . . . . . . . 76-77

R
Radiator and Cooling Fan . . . . . . . . . 73
Radiator Coolant Level . . . . . . . . . . . 74
Rear Gearcase . . . . . . . . . . . . . . . . 68-69
Rear Spring Adjustment . . . . . . . . . . 84
Removal from Storage . . . . . . . . . . . 98

S
Seat Belts . . . . . . . . . . . . . . . . . . 28, 85
Seat Removal . . . . . . . . . . . . . . . . . . 27
Sidehilling . . . . . . . . . . . . . . . . . . . . 40
Spark Arrestor . . . . . . . . . . . . . . . . . . 79
Spark Plug Removal . . . . . . . . . . . . . 71

T
Throttle Body . . . . . . . . . . . . . . . . . . 81
Throttle Freeplay . . . . . . . . . . . . . . . . 80
Throttle Pedal . . . . . . . . . . . . . . . . . . 32
Throttle System . . . . . . . . . . . . . . . 80-81
Tire Tread Depth . . . . . . . . . . . . . . . . 86
Tires . . . . . . . . . . . . . . . . . . . . . . . 86-87
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 90
Torque Specifications . . . . . . . . . . . . 86
Towing Capacities . . . . . . . . . . . . . . . 48
Towing Loads . . . . . . . . . . . . . . . . . . 48
Trailer Hitch Bracket . . . . . . . . . . . . . 26
Transmission . . . . . . . . . . . . . . . . . 64-65
Transporting the RANGER . . . . . . . . 98
Troubleshooting . . . . . . . . . . . . 104-106

V
Vehicle Break-In Period . . . . . . . . . . 33
Vehicle Identification Numbers . . . . . . 4
Vehicle Immersion . . . . . . . . . . . . . . 91

W
Warranty . . . . . . . . . . . . . . . . . . 107-115
Wheel Installation . . . . . . . . . . . . . . . 87
Wheel Removal . . . . . . . . . . . . . . . . 87

119

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