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The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WARNING

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.

SSnowmobiles

SAll-terrain vehicles (ATVs)

SRANGER utility vehicles

SVictory 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!

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.

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):

31XX

SAFETY

Operator 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

Acaution indicates a situation that may result in damage to the

vehicle.

NOTE:

Anote will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these

instructions and procedures, which are outlined in further detail

within your owner’s manual.

SRead this manual and all labels carefully. Follow the operating pro-

cedures described.

SNever allow anyone without a valid driver’s license to operate this

vehicle.

SMinimum age recommendation for passengers is five years old. Pas-

sengers 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.

SNever permit a guest to operate this vehicle unless the guest has read

this manual and all product labels.

STo reduce tipover risk, be especially careful when encountering ob-

stacles and slopes and when braking on hills or during turns.

SThis vehicle is for off road use only. Never operate on public roads.

Always avoid paved surfaces.

SHelmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

SNever consume alcohol or drugs before or while operating this ve-

hicle.

SNever operate at excessive speeds. Always travel at a speed proper

for the terrain, visibility and operating conditions, and your experi-

ence.

SNever attempt wheelies, jumps or other stunts.

SAlways inspect your vehicle each time you use it to make sure it’s in

safe operating condition. Always follow the inspection and mainte-

nance procedures and schedules described in this manual.

SAlways keep both hands on the steering wheel and both feet on the

floorboards of the vehicle during operation.

SAlways travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain.

SNever operate on excessively rough, slippery or loose terrain.

SAFETY

Operator Safety

SAlways 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.

SAlways have this vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

SNever operate this vehicle on hills too steep for the vehicle or for

your abilities. Practice on smaller hills before attempting larger hills.

SAlways 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.

SAlways follow the proper procedures outlined in this manual for

traveling downhill and for braking on hills. Check the terrain care-

fully 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 pos-

sible.

SAlways 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.

SAlways 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.

SNever 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.

SAlways 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.

SAlways use the proper size and type of tires specified in this manual.

Always maintain proper tire pressure as specified on page 19.

SAFETY

Operator Safety

SNever modify this vehicle through improper installation or use of

accessories.

SNever 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.

SAlways wear the seat belts when operating this vehicle. Seat belts

reduce the severity of injury in case of a sudden stop or collision.

SAlways keep arms and legs inside the cab frame while the vehicle is

in motion.

SAlways engage the park brake before getting out of the vehicle. See

page 32.

SAlways apply the service brakes before releasing the park brake.

SAlways 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 instruc-

tions.

SAlways 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.

SAFETY

Operator 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.

Ifyouloseallforwardspeed:

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.

SAFETY

Operator 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.

SAFETY

Operator 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.

SAFETY

Operator 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.

WARNING

SMoving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle

with guard removed.

SDo 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

7172563

Location 1

SAFETY

Safety Decals and Locations

WARNING

SVEHICLE ROLLOVER could cause severe injury or death.

This cab frame is not designed or intended to provide rollover protection.

SALWAYS 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.

SPassengers can be thrown off. This can cause serious injury or death.

SNever 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)

Location 6

Location 7

ATTENTION

SOperation of this vehicle without the air filter

element will severely damage the engine.

SClean pre-filter element often, more

frequent cleaning required in dusty

conditions. Do not operate vehicle without

pre-filter.

7172921

SAFETY

Safety Decals and Locations

Discretionary Warning Decal

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. Cab Frame (if equipped)

2. Hip Bar

3. Console

4. Steering Wheel

5. Seat

6. Storage Box (under driver’s seat)

7. Cargo Box

8. Seat Belts

9. Fuel Tank Cap / Fuel Gauge

10. Battery (under hood)

11. Storage Box (under hood)

FEATURES AND CONTROLS

Component Locations

12. Headlights

13. Radiator (if equipped)

14. Front Bumper/Brush Guard

15. Hood Hold Down Strap

14 13

FEATURES AND CONTROLS

Component Locations

16. Taillights

17. Tailgate

18. Tailgate Latch Release

19. Muffler (Spark Arrester)

20. CV Boot/Rear Caliper

21. Air Box

22. Receiver Hitch

FEATURES AND CONTROLS

Indicator Lights

1. High Gear

2. Low Gear

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. 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.

642

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.

FEATURES AND CONTROLS

Console

1. Cup Holder

2. Indicator Lights

3. Shift Lever

4. Light Switch

5. AWD/Differential Switch (if equipped)

6. Hour Meter

7. Glove Box with Lid

8. 12V Accessory Plug

9. Storage Tray

10. Ignition Switch

11. Storage Box

FEATURES AND CONTROLS

Gear Selector

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

NOTE: 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.

FEATURES AND CONTROLS

Switches

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

positions:

A: High Beam

B: Low Beam

C: Off

AWD/Differential Lock Switch (3)

The AWD/Differential Switch has three positions:

D: AWD

E: Differential Lock (2WD)

F: Off (1WD)

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.

AWD

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.

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.

OPERATION

Vehicle Break-In Period

The break-in period for your new Polaris RANGER is the first twenty

hours of operation, or the time it takes to use the first two tanks full of

gasoline. No single action on your part is as important as a proper

break-in period. Careful treatment of a new engine will result in more

efficient performance and longer life for the engine. Perform the

following procedures carefully.

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 82

Brake fluid Ensure proper level 82

Front suspension Inspect, lubricate if necessary 58

Rear suspension Inspect, lubricate if necessary 58

Steering Ensure free operation --

Tires Inspect condition and pressure 86,101

Wheels / fasteners Inspect, ensure fastener tightness 86

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 61

Coolant level Ensure proper level 73

Coolant hoses Inspect for leaks --

Throttle Ensure proper operation 32

Indicator lights / switches Ensure operation 26, 31

Air filter, pre-filter Inspect, clean 78

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

1. Sit in the driver’s seat and fasten the seat belt.

2. Engage the park brake.

3. Shift the transmission to neutral.

4. 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.

OPERATION

Driving Safely

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

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.

15_Maximum

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 toaidinslowing.

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.

OPERATION

Driving Safely

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

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.

OPERATION

Driving Safely

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

ParkingonanIncline

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.

OPERATION

Driving Safely

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.

OPERATION

Driving Safely

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.

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

Load Weight

(level ground)

Total Towed

Load Weight

(15°grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

RANGER

4x4 XP

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER

6X6 EFI

1750 lbs.

(794 kg)

1000 lbs.

(454 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

Belt Life

To extend belt life, use the lowest gear possible when hauling or

towing heavy cargo.

OPERATION

Driving Safely

Parking the RANGER

WARNING

A rolling vehicle can cause property damage and serious injury.

Always engage the park brake after stopping the engine.

1. Stop the vehicle on a level surface.

2. Turn the engine off.

3. Engage the park brake.

4. 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.

CAUTION

Damage to the differential can occur if it is engaged while the

vehicle is traveling at high speeds or while the rear wheels are

spinning. Slow the vehicle to nearly stopped before engaging the

differential.

AWD

OPERATION

All Wheel Drive (AWD)

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

SFrequent immersion in mud, water or sand

SRacing or race-style high RPM use

SProlonged low speed, heavy load operation

SExtended idle

SShort 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

"Perform these procedures more frequently for vehicles subjected to

severe use.

EEmission Control System Service - 4 Cycle (California)

JHave an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Jcould

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)

Remarks

Hours Calendar Miles

(Km)

JSteering -- Pre-Ride -- Make adjustments as need-

"Front suspension -- Pre-Ride --

ed. See Pre-Ride Checklist

on pa

e 34.

"Rear suspension -- Pre-Ride --

Tires -- 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

tube

-- Daily -- Drain deposits when visible

Coolant

(if applicable)

-- Daily -- Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

-- Daily -- Check operation; apply

dielectric grease if replacing

Air filter,

main element

-- Weekly -- Inspect; replace as needed

Brake pad wear 10 H Monthly -- Inspect periodically

Battery 20 H Monthly -- Check terminals; clean; test

"Front gearcase oil

(if equipped)

25 H Monthly -- Inspect level; change yearly

"Middle gearcase

oil (if equipped)

25 H Monthly -- Inspect level; change yearly

"Rear gearcase oil

(if equipped)

25 H Monthly -- Inspect level; change yearly

"Transmission oil 25 H Monthly -- Inspect level; change yearly

"Perform these procedures more often for vehicles subjected to severe use.

EEmission Control System Service - 4 Cycle (California)

JHave an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Engine breather

filter (if equipped)

25 H Monthly -- Inspect; replace if necessary

"Engine oil change

(break-in)

25 H 1M -- Perform a break-in oil

change at one month

"General

lubrication

50 H 3M -- Lubricate all fittings, pivots,

cables, etc.

Shift Linkage 50 H 6M -- Inspect, lubricate, adjust

JSteering 50 H 6M -- Lubricate

"Front suspension 50 H 6M -- Lubricate

"Rear suspension 50 H 6M -- Lubricate

Throttle Cable/

ETC Switch

50 H 6M -- Inspect; adjust; lubricate;

replace if necessary

EThrottle body air

intake ducts/

flange

50 H 6M -- Inspect ducts for proper

sealing/air leaks

Drive belt 50 H 6M -- Inspect; adjust; replace as

needed

Cooling system

(if applicable)

50 H 6M -- Inspect coolant strength

seasonally; pressure test

system yearly

"Engine oil change 100 H 6M -- Perform a break-in oil

change at 25 hours/one

month

"Oil filter change 100 H 6M -- Replace with oil change

"Perform these procedures more often for vehicles subjected to severe use.

EEmission Control System Service - 4 Cycle (California)

JHave an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Fuel system 100 H 12 M -- Check for leaks at tank cap,

lines, fuel valve, filter, pump,

throttle body; replace lines

every two years

JFuel filter 100 H 12 M -- Replace yearly

"Radiator

(if applicable)

100 H 12 M -- Inspect; clean external

surfaces

"Cooling hoses

(if applicable)

100 H 12 M -- Inspect for leaks

"Engine mounts 100 H 12 M -- Inspect

Exhaust muffler/

pipe

100 H 12 M -- Inspect

Spark plug 100 H 12 M -- Inspect; replace as needed

JIgnition Timing 100 H 12 M -- Inspect

"Wiring 100 H 12 M -- Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

JClutches (drive

and driven)

100 H 12 M -- Inspect; clean; replace worn

parts

JFront wheel

bearings

100 H 12 M -- Inspect; replace as needed

JBrake fluid 200 H 24 M -- Change every two years

Spark arrestor 300 H 36 M -- Clean out

Idle speed -- Adjust as needed

JToe adjustment -- Inspect periodically; adjust

when parts are replaced

Auxiliary brake (if

equipped)

-- Inspect daily; adjust as

needed

Headlight aim -- Adjust as needed

"Perform these procedures more often for vehicles subjected to severe use.

EEmission Control System Service - 4 Cycle (California)

JHave 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

LPolaris Premium all Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

FUse 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 Syn-

thetic 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

(1)

(3)

6X6

4X4

6X6

(2)

4X4

6X6

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

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.

6. After reinstalling the dipstick, be

sure to seat the lever lock.

SAFE ADD 8 OZ

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)

14 ft. lbs.

(19.4 Nm)

Front Gearcase Premium Demand

Drive Hub Fluid

5oz.

(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)

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)

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. 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.

Oil Change

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.

6X6

4X4

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

oil as needed.

4. Reinstall the fill plug.

Torque to specification.

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)

18 ft. lbs.

(24 Nm)

RANGER

6X6 EFI .035″(.9 mm) 18 ft. lbs.

(24 Nm)

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.

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: 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.

NOTE: 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

SWhen basic operation is at speeds less than 7 MPH (11 KPH)

SFor heavy pulling

SWhen operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

SWhen basic operation is at speeds greater than 7 MPH (11 KPH)

SWhen 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.

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

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.

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.

123

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. 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.

MAINTENANCE AND LUBRICATION

Brakes

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).

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.

3/64″(1 mm)

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).

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.

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)

1/8I(3 mm)

MAINTENANCE AND LUBRICATION

Tires

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.

MAINTENANCE AND LUBRICATION

Lights

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.

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. Reach in behind the console

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:

SA screwdriver

SAn open-end wrench (8-10 mm)

SAn open-end wrench (12-14 mm)

SA tire pressure gauge

SA spark plug wrench and handle

SA 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. Thoroughly dry the air pre-cleaner located under the hood.

4. Remove the spark plugs.

5. Turn the engine over several times using the electric start.

6. Dry the spark plugs and reinstall, or replace with new plugs.

7. 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.

MAINTENANCE AND LUBRICATION

Battery

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

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

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)

Gearcase / Transmission Lubricants

2873602 Premium AGL Synthetic Gearcase Lube (qt.)

2873603 Premium AGL Synthetic Gearcase Lube (gal.)

2871653 Premium ATV Angle Drive Fluid (8 oz.)

2872276 Premium ATV Angle Drive Fluid (2.5 gal.)

2870465 Pump for Gallon Jug

2871654 Premium Demand Drive Hub Fluid (8 oz.)

2872277 Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

2871322 Premium All Season Grease (3 oz. cartridge)

2871423 Premium All Season Grease (14 oz. cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz.)

2871551 Premium U-Joint Lube (14 oz.)

2871312 Grease Gun Kit

2871329 Dielectric Grease (Nyogelt)

2872073 Chain Lube (6.25 oz. aerosol)

2872348 Chain Lube (16 oz. aerosol)

Coolant

2871323 60/40 Coolant (gal.)

2871534 60/40 Coolant (qt.)

Additives / Miscellaneous

2872889 Brake and Clutch Cleaner

2871326 Carbon Clean Plus (12 oz.)

2870652 Fuel Stabilizer (16 oz.)

2870990 DOT3 Brake Fluid

2872893 Engine Degreaser

2871956 LOCTITE 565 Thread Sealant

100

SPECIFICATIONS

RANGER 4X4 XP

Gross Vehicle Weight 2750 lbs. (1247 kg)

Dry Weight 1185 lbs. (537 kg)

Fuel Capacity 8gal.(30.3l)

Engine Oil Capacity 2qts.(2.1l)

Coolant Capacity 3.25 qts. (3 l)

Towing Capacity 1500 lbs. (681 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load 1000 lbs. (454 kg)

Overall Length 113 in. (282 cm)

Overall Width (box) 60 in. (152.4 cm)

Overall Width (tires) 58 in. (147.3 cm)

Overall Height 75 in. (190.5 cm)

Wheelbase 76 in. (193 cm)

Cargo Box

(LxWxH)

58x42x10in.

(147 x 106.7 x 25.4 cm)

Ground Clearance 11.5 in. (29 cm)

Min. Turning Radius 132 in. (335.3 cm)

Engine 4 valve 4 stroke twin cylinder with

counter balance

Displacement 683 cc

Bore x Stroke 80x68

Alternator Output 500 W @ 3000 RPM

Compression Ratio 9.40:1

Starting System Electric

Fuel System Electronic Fuel Injection

Ignition System ECU

SparkPlug/Gap RC7YC / .035 in. (0.9 mm)

Front Suspension MacPherson strut

w/8 in. (20.3 cm) of travel

Rear Suspension Independent

w/9.0 in. (22.9 cm) of travel

101

SPECIFICATIONS

RANGER 4X4 XP

Lubrication System Pressurized Wet Sump

Engine Oil 0W/40

Driving System Type PVT, 4-wheel independent shaft,

lockable differential

Shift Type Single Lever (H/L/N/R)

Gear Reduction - Low 8.71:1

Gear Reduction - Reverse 5.94:1

Gear Reduction - High 3.14:1

Drive Ratio - Front: 3.83:1

Drive Ratio - Final 3.70:1

Tire Size - Front 26x8-12

Tire Size - Rear 26x11-12

Tire Pressure - Front 8-12 psi

Tire Pressure - Rear 8-12 psi

Brakes, Front/Rear Foot Activated,

4 wheel hydraulic disc

Brake, Park Foot activated, mechanical

Hood Headlight 2 dual beam, 35W, quartz/halogen

Taillights 2 single beam, 5W

Brake Light 2 single beam, 5W

Indicator Light 1.0 W

NOTE: See your Polaris dealer for clutching specifications.

102

SPECIFICATIONS

RANGER 6X6 EFI

Gross Vehicle Weight 2900 lbs. (1317 kg)

Dry Weight 1410 lbs. (640 kg)

Fuel Capacity 8gal.(30.3l)

Engine Oil Capacity 2qts.(2.1l)

Coolant Capacity 3.25 qts. (3 l)

Towing Capacity 1750 lbs. (794 kg)

Max. Cargo Box Load 1250 lbs. (567 kg)

Overall Length 120 in. (304.8 cm)

Overall Width (box) 60 in. (152.4 cm)

Overall Width (tires) 58 in. (147.3 cm)

Overall Height 75 in. (190.5 cm)

Wheelbase 90 in. (228.6 cm)

Ground Clearance 7.2 in. (18 cm)

Min. Turning Radius 180 in. (457.2 cm)

CargoBox(LxWxH) 58x48x10in.

(147 x 122 x 25.4 cm)

Engine 4 valve 4 stroke twin cylinder

with counter balance

Displacement 683 cc

Bore x Stroke 80x68

Alternator Output 500 W @ 3000 RPM

Compression Ratio 9.40:1

Starting System Electric

Fuel System Electronic Fuel Injection

Ignition System ECU

SparkPlug/Gap RC7YC / .035 in. (0.9 mm)

Lubrication System Pressurized Wet Sump

Engine Oil 0W/40

103

SPECIFICATIONS

RANGER 6X6 EFI

Front Suspension MacPherson strut

w/6.25 in. (15.9 cm) of travel

Center Suspension Independent

w/5.25 in. (13.3 cm) of travel

Rear Suspension Swing arm w/dual shocks

w/6.25 in. (15.9 cm) of travel

Driving System Type PVT

Shift Type Single Lever (console)

Gear Reduction - Low 8.71:1

Gear Reduction - Reverse 5.9:1

Gear Reduction - High 3.14:1

Drive Ratio - Front: 3.83:1

Drive Ratio - Final 3.70:1

Tire Size - Front 25x10-12

Tire Size - Center/Rear 25x11-12

Tire Pressure - Front 8-12 psi

Tire Pressure - Center/Rear 8-12 psi

Brakes, Front/Rear Foot Activated,

4 wheel hydraulic disc

Brake, Parking Foot activated, mechanical

Hood Headlight 2 dual beam, 35W, quartz/halogen

Taillights 2 single beam, 5W

Brake Light 2 single beam, 5W

Indicator Light 1.0 W

NOTE: See your Polaris dealer for clutching specifications.

104

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

105

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

106

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

107

WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-

ITED WARRANTY on all components of the Polaris RANGER against defects in mate-

rial 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 entitle-

ment. 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 ma-

terial 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, com-

ponents or the vehicle caused by fire, explosions or any other cause beyond Polaris’ con-

trol.

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 DE-

SCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY

OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-

WISE. Some states do not permit the exclusion or limitation of incidental or consequen-

tial damages or implied warranties, so the above limitations or exclusions may not apply

to you if inconsistent with controlling state law.

108

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES 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 Registra-

tion 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 mainte-

nance and installation are in accordance with Polaris recommendations.

109

WARRANTY

Exported Vehicles

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 per-

sonnel 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 per-

form 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 docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. 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 war-

ranty 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

110

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 en-

gine’s emissions, including electronic controls, fuel injection, exhaust-gas recirculation,

aftertreatment, or any other system utilized in this vehicle to control emissions. Replac-

ing 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 CON-

TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR 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 workman-

ship. 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.

111

WARRANTY

California Emission Control Warranty Statement

Your Warranty Rights and Obligations

The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Me-

dina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control

system warranty on your Large Spark Ignition Engine (herein “LSI engine”). “The Cali-

fornia 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 sys-

tem. 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.

The Air Index of this Engine is 3

0246810

Most Clean

Note: The lower the Air Index, the less pollution.

This engine is certified to be emission compliant

for 1000 hours of use.

Least Clean

112

WARRANTY

California Emission Control Warranty Statement

Owner’s Warranty Responsibilities:

SAs the LSI engine owner, you are responsible for the performance of the required

maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-

er’s Manual”). POLARIS recommends that you retain all receipts covering mainten-

ance 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.

SAs 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.

SYou are responsible for presenting your LSI engine to a dealer authorized by PO-

LARIS 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 con-

form 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 origi-

nal retail purchaser and ends two years after that date. During this two year period PO-

LARIS 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.

113

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, PO-

LARIS will repair and/or replace the necessary components.

114

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 emis-

sion-related part unless performed by an authorized dealer

(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.

115

WARRANTY

Maintenance Schedule Key

"Perform these procedures more often for vehicles subjected to severe use.

EEmission Control System Service (California)

JHave an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Air filter, pre-filter -- Daily -- Inspect; clean often

Air box sediment

tube

-- Daily -- Drain deposits when visible

Air filter,

main element

-- Weekly -- Inspect; replace as needed

Engine breather

filter (if equipped)

25 H Monthly -- Inspect; replace if necessary

Throttle Cable/

ETC Switch

50 H 6M -- Inspect; adjust; lubricate; re-

place if necessary

EThrottle body air

intake ducts/

flange

50 H 6M -- Inspect ducts for proper

sealing/air leaks

Valve clearance 100 H 12 M -- Inspect; adjust

Fuel system 100 H 12 M -- Check for leaks at tank cap,

lines, fuel valve, filter, pump,

throttle body; replace lines

every two years

Spark plug 100 H 12 M -- Inspect; replace as needed

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 Ser-

vice

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.

116

MAINTENANCE LOG

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

117

MAINTENANCE LOG

DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

118

INDEX

Age Restrictions 5.................

Air Filter 78......................

All Wheel Drive (AWD) 51..........

Auxiliary Outlet 26................

AWD Switch 31...................

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.......................

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.

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..........

Electromagnetic Interference 52.......

Emission Control Systems 52........

Emissions Warranty 110............

Engine Oil 60-63...................

Equipment Modifications 10.........

Exhaust Emission Control System 52..

Filter Systems 78..................

Front Gearcase 66.................

Fuel Cap 27......................

Fuel Filter 78.....................

Fuel Gauge 27....................

Fuel Safety 22....................

Gear Selector 30...................

Gearcase Specification Chart 63.......

Gearcases 63-69...................

Hauling Cargo 45-46................

Headlight Beam Adjustment 89.......

High Range 75....................

Idle RPM 81.....................

Ignition Switch 31.................

Indicator Lamp Replacement 90......

Indicator Lights 26.................

Light Switch 31...................

Lights 88-90......................

Low Range 75....................

Lubrication Recommendations 58-59...

Main Gearcase 64-65...............

Maintenance Chart 53-57............

Maintenance Log 116-117...........

Middle Gearcase 67................

119

INDEX

Noise Emission Control System 52....

Oil and Filter Change 62-63..........

Oil Check 61.....................

Operator Safety 5-17................

Park Brake Adjustment 83...........

Park Brake Inspection 83............

Park Brake Pedal 32................

Park Brake Release 32..............

ParkingonanIncline 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.................

Radiator and Cooling Fan 73.........

Radiator Coolant Level 74...........

Rear Gearcase 68-69................

Rear Spring Adjustment 84..........

Removal from Storage 98...........

Seat Belts 28, 85..................

Seat Removal 27..................

Sidehilling 40....................

Spark Arrestor 79..................

SparkPlugRemoval 71.............

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......................

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............

Vehicle Break-In Period 33..........

Vehicle Identification Numbers 4......

Vehicle Immersion 91..............

Warranty 107-115..................

Wheel Installation 87...............

Wheel Removal 87................

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