Polaris Phoenix 2005 99 Ranger

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WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.

FOREWORD
Congratulations and thank you from Polaris Industries Inc. for purchasing one of
our products. Built with American engineering and manufacturing know-how, it is
designed to provide superior comfort, utility, enjoyment and safety.
This manual is furnished to ensure that the operator is aware of safe operating pro-
cedures. It also includes information about the general care and maintenance of
your vehicle.
Carefully read the following pages. If you have any questions regarding this ve-
hicle contact a Polaris dealer for assistance. Remember, Polaris dealers have the
knowledge and facilities to provide you with the best service possible.
PROTECT YOUR SPORT
Know all local, state/province off-road vehicle laws;
Respect your vehicle;
Respect the environment; and
You will gain the respect of others.
We also advise you to strictly follow the recommended maintenance program as

outlined. This preventive maintenance program is designed to ensure that all criti-
cal components on this vehicle are thoroughly inspected at various intervals.
All information in this manual is based upon the latest product data and specifica-
tions available at the time of printing. Polaris Industries Inc. reserves the right to
make product changes and improvements which may affect illustrations or ex-
planations.
No part of this manual shall be reproduced or used without the written permission
of Polaris Industries Inc.

THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
This vehicle handles differently from other vehicles including motor-
cycles and cars. A collision or rollover can occur quickly, even during rou-
tine maneuvers such as turning and driving on hills or over obstacles, if you
fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures
described.
Never allow anyone without a valid driver’s license to operate this vehicle.
Minimum age recommendation for passengers is five years old. Passengers
under five years of age require special restraints which are not available with this
vehicle. Driver and passenger should wear their seatbelts at all times.
Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
To reduce tipover risk, be especially careful when encountering obstacles and
slopes, when braking on hills or during turns.
Always fasten your seatbelts securely around you.
This vehicle is for off road use only. Never operate on public roads as severe
injury or death may occur. Always avoid paved surfaces.
Helmets are recommended whenever driving this vehicle in an aggressive man-
ner. Eye protection is recommended at all times.
Never consume alcohol or drugs before or while operating this vehicle.
Never operate at excessive speeds. Always travel at a speed which is proper
for the terrain, visibility and operating conditions, and your experience.
Never attempt wheelies, jumps or other stunts.
Always inspect your vehicle each time you use it to make sure it is in safe operat-
ing condition. Always follow the inspection and maintenance procedures and
schedules described in this manual.
Always keep both hands on the steering wheel and both feet on the floorboards
of the vehicle during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Al-
ways be alert to changing terrain conditions when operating this vehicle.
Never operate on excessively rough, slippery or loose terrain.
Always follow proper procedures for turning as described in this manual. Prac-
tice turning at low speeds before attempting to turn at faster speeds. Do not turn
at excessive speed.
Always have this vehicle checked by an authorized Polaris dealer if it has been
involved in an accident.
Never operate this vehicle on hills too steep for the vehicle or for your abilities.
Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described in this manual.
Check the terrain carefully before you start up any hill. Never climb hills with ex-
cessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly or make sudden gear changes. Never go over the top of any
hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as
described in this manual. Check the terrain carefully before you start down any
hill. Never go down a hill at high speed. Avoid going down a hill at an angle
which would cause the vehicle to lean sharply to one side. Go straight down the
hill where possible.
Always follow proper procedures for crossing the side of a hill as described in
this manual. Avoid hills with excessively slippery or loose surfaces. Never at-
tempt to turn the vehicle around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of
a steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a hill.
To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual.
Dismount on the uphill side or to either side if pointed straight uphill. Turn the
vehicle around and remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
Always be careful of skidding or sliding. On slippery surfaces, such as ice, go
slowly and be very cautious in order to reduce the chance of skidding or sliding
out of control.
Never operate vehicle in fast flowing water or in water deeper than that specified
in this manual. Remember that 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.
Always be sure there are no obstacles or people behind you when you operate
in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at
sharp angles in reverse.
Always use the size and type tires specified in this manual. Always maintain
proper tire pressure as described on page 83.
Never modify this vehicle through improper installation or use of accessories.
Never exceed the stated load capacity for this vehicle. Cargo should be proper-
ly distributed and securely attached. Reduce speed and follow instructions in
this manual for carrying cargo or pulling a trailer. Allow greater distance for brak-
ing.
Always wear the seat belts whenever the vehicle is operated. This will reduce
the severity of injury in case of a sudden stop or collision.
Always keep arms and legs inside of cab frame while the vehicle is in motion.
Always apply the parking brake before getting out of the vehicle. The parking
brake is located on the left side of the center console. Activate by pulling up on
the lever. Release by pressing the button on the end of the handle and lowering
the lever.
Always activate the foot pedal brake before releasing the park brake.
Always shut off the engine before refueling. Make sure the area is well venti-
lated and free of any source of flame or sparks. Gasoline is very flammable.
See page 24 for refueling instructions.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.

indicates a potential hazard which
WARNING could result in serious injury or death.
Additional Important Information...
Due to our concern for the safety of our customers and the general public, Polaris
hereby strongly recommends and requests that consumers not have installed on
a Polaris RANGER any equipment which is intended to increase the speed or pow-
er of the vehicle; or make any other modifications to the vehicle for these purposes.
Any modifications to the original equipment of the RANGER substantially increase
the risk of bodily injury. Please be aware that these modifications may create a sub-
stantial safety hazard.
Polaris hereby informs you that the warranty on your RANGER is terminated if any
such equipment has been added to the vehicle or any modifications have been
made to the vehicle which increase its speed or power.
We also advise you to strictly follow the recommended maintenance program out-
lined in this manual. This preventive maintenance program is designed to ensure
that all critical components on the vehicle are thoroughly inspected by your dealer
at various mileage intervals.
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 ve-
hicle.
Be certain any accessories added to this vehicle have been approved by Polaris.
Familiarize yourself with their function and affect on the vehicle.

The Polaris Preferred
Registered Owners
(PRO) Family
Your Owners Program
As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem-
bership in the Polaris PRO Family-–the Preferred Registered Owners Family. It’s
an owners program for Polaris owners like you, people who have chosen the finest
recreational vehicle available, people who share an interest in Polaris and its prod-
ucts.
Once your new vehicle’s warranty is registered, you will receive a PRO Family
membership packet that will include:
A letter of welcome to the PRO Family
A PRO Family card with your name and membership number
A colorful sticker of the PRO logo
A PRO merchandise brochure and order form.
As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the PRO Family
The chance to buy insurance for you Polaris vehicle. The toll-free insurance
telephone number is: 1-800-473-0111
The chance to arrange travel through the Polaris Travel Center. The toll-free
travel telephone number is: 1-800-267-1915
The chance to apply to serve on PRO Consumer Councils that provide input
into the Polaris vehicles of the future
The chance to serve as a PRO Field Evaluator and provide feedback on your
new vehicle
The chance to purchase exclusive PRO Family merchandise
And more!
To order PRO merchandise, you’ll complete the order form you receive with your
membership packet, take the form to your Polaris dealer and pay for the merchan-
dise. The merchandise will be shipped directly to your home from the PRO mer-
chandise fulfillment center.
Watch for your PRO membership packet and the next issue of PRO Spirit maga-
zine. This quarterly magazine will keep you informed about Polaris news and
events, and special PRO merchandise, travel, and ride opportunities.
Enjoy your new Polaris vehicle, and welcome to the family--The Polaris PRO Fami-
ly.

CONTENTS
UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY WARNING AND OPERATION DECALS . . . . . . . . . . . . 2-7
LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DAILY PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . 20
CONTROL AND PARTS FUNCTIONS . . . . . . . . . . . . . . . . . . . 21-39
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
VEHICLE BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CARRYING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-55
NOISE EMISSION CONTROL SYSTEM REGULATION . . . . . . . 56
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571–58
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-88
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-91
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

UNDERSTANDING WARNINGS
SAFETY ALERT
The following precautionary signal words are used throughout this manual to con-
vey the following messages:
This is the safety alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury. Your safety is involved!
Indicates a potential hazard

WARNING which could result in serious
injury or death.
Indicates a potential hazard which

CAUTION may result in minor personal inju-
ry or damage to the vehicle.
The word “NOTE:” in this manual will alert

NOTE you to key information or instructions.
WARNING
HAZARD
Failure to heed WARNINGS.
WHAT CAN HAPPEN

WARNINGS identify special instructions or procedures which, if not cor-
rectly followed, could result in personal injury , or loss of life.
HOW TO AVOID THE HAZARD

Read all WARNINGS in this manual carefully and for your safety be
sure to follow their instructions.

SAFETY WARNING AND OPERATION DECALS
WARNING
VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATH
This cab frame is not designed or intended to provide rollover protection
in the event of vehicle overturning. See Owner’s Manual.
7077478
l Riders can be thrown off.

This can cause serious in-
jury or death.
l Never carry riders in cargo
box. 7077681
TRAILER MAX.
WEIGHT 1500 LBS.
HITCH MAX. VERTICAL
WEIGHT 150 LBS. 7077682
IMPROPER TIRE PRESSURE OR OVER-

LOADING CAN CAUSE LOSS OF CONTROL.
LOSS OF CONTROL CAN RESULT IN
SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI):
FRONT MIN. 5 MAX. 12
CENTER & REAR MIN. 5 MAX. 10
MAXIMUM WEIGHT CAPACITY
(Gross Vehicle Weight)
INCLUDING MACHINE, PASSENGER
AND CARGO IS 2920 LBS.
SEE OWNER’S MANUAL FOR PROPER
TIRE INFLATION FOR DIFFERENT VEHICLE
APPLICATIONS.
7077475

HEADLAMPS ARE NOT SEALED.

DO NOT SUBMERGE OR APPLY
WATER PRESSURE DIRECTLY ONTO
SERVICE OPENING.
Recoil handle must be firmly seated to

prevent water entry. Drain starter motor
if water enters. See owner’s manual.
7075741
WARNING/AVERTISSEMENT
This vehicle is designed for operator and
“ONE” passenger only
Ce Vehicule est concu pour ne transporter
que le conducteur et “UN SEUL” passager.
7075439
WARNING
DO NOT ATTEMPT ENGINE OR
CLUTCH MODIFICATION. DOING SO
CAN CAUSE IMBALANCE AND/OR
EXCESSIVE ENGINE RPM.
EXCESSIVE ENGINE RPM CAN CAUSE
PART FAILURE RESULTING IN
POSSIBLE SEVERE INJURY OR
DEATH.
DO NOT MODIFY ENGINE OR CLUTCH.
7077377

7077683
Text found below
OPERATOR/LOAD DISTRIBUTION WARNINGS

VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSS
OF CONTROL AND RESULT IN SEVERE INJURY OR DEATH.
MAKE STARTS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTH
MANNER so as not to shift the load or overturn the vehicle.
THE FOOT BRAKE PEDAL CONTROLS THE PRIMARY BRAKING for this ve-
hicle.
THE PARK/EMERGENCY BRAKE LEVER will supply increased braking, but
should be used as an EMERGENCY OR PARKING BRAKE ONLY.
THE BOX DUMP LATCH MUST BE SECURELY LATCHED before loading and op-
erating. Unintentional box dumping will result if weight is placed in the rear of the
box and the latch is not secured.
NEVER OPERATE THIS VEHICLE WITH THE DUMP BOX IN THE RAISED
POSITION. The dump box could close unexpectedly while driving, severely injur-
ing the driver and passenger. The rear tires will catch the rear of the box, damaging
the vehicle and creating hazardous driving conditions.
THE VEHICLE BRAKING PERFORMANCE IS REDUCED WHEN CARRYING
LOADS. Reduce speeds and allow for greater stopping distances when operating
in a loaded or trailering condition.

THE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING IN
A LOADED CONDITION on rough or hilly terrain. When climbing hills always hav-
ing the cargo in the rear box securely fastened and located as far forward in the box
as possible. Loaded vehicles will experience reduced steering and front brake ef-
fectiveness when operating on hills.
TO REDUCE THE CHANCE OF VEHICLE TIP-OVER AND PERSONAL INJURY
always use D-1 Gear and reduced vehicle speeds when carrying heavy loads or
towing a loaded trailer.
Correct loading of this vehicle is necessary to maintain proper stability and operat-
ing characteristics. Overloading or incorrect positioning of the load effects the ve-
hicles turning, stopping distance and stability. Failure to follow loading require-
ments could cause severe injury or death. REDUCE SPEED AND ALLOW
GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.
MAXIMUM CARGO CAPACITY IS 1000 LBS. ON LEVEL TERRAIN. When oper-
ating over rough or hilly terrain, reduce speed and cargo to maintain stable driving
conditions. When operating at maximum cargo capacity, the cargo weight must be
evenly distributed in the rear box.
ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured
loads can create unstable operating conditions which could result in loss of control
of the vehicle.
LOADS MUST BE CARRIED AS LOW IN THE BOX AS POSSIBLE. Carrying
loads high in the box raises the center of gravity of the vehicle and creates a less
stable operating condition. When cargo loads are carried high in the box, the
weight of the loads must be reduced to maintain stable operating conditions.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When han-
dling off-centered loads which cannot be centered, securely fasten load and oper-
ate with extra caution.
EXTREME CAUTION MUST BE USED when operating with loads extending over
the box sides. Stability and maneuverability may be adversely affected, causing
the machine to overturn.
SEE YOUR OWNER’S MANUAL.

7077680
Text found below
READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFORE

OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING
WARNINGS OR IMPROPER USE. If you do not have the Owner’s Manual for this
vehicle, call 1-800-324-3674 to have one provided at no extra charge.
This vehicle REQUIRES SPECIAL RIDING SKILLS due to its handling.
Ride within your skill.
THIS VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A
VALID DRIVER’S LICENSE. Operation by unlicensed operators increases
the risk of severe injury or death.
MINIMUM AGE RECOMMENDATION FOR PASSENGERS IF FIVE YEARS
OLD. Passengers under five years of age require special restraints which
are not available with this vehicle. Driver and passenger should wear their
seat belts at all times.
THIS VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rol-
lover can occur quickly, even during routine maneuvers such as turning, driv-
ing on hills or over obstacles, if you fail to take proper precautions.
TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN EN-
COUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS
OR DURING TURNS.
KEEP FEET ON FLOORBOARDS AT ALL TIMES.
ALWAYS FASTEN YOUR SEATBELTS SECURELY AROUND YOU.

OPERATION ON HILLS IS DANGEROUS, especially when loaded. This
vehicle is designed for utility usage on moderate terrains. Turning, braking
and uneven terrain can induce rollovers especially if a maneuver is abrupt.
Under no circumstances should you climb, descend or traverse hills greater
than 15°∠. Vehicle stability is greatly reduced during operating on hills,
creating the possibility of vehicle rollover and serious injury, including death
or paralysis. Extreme caution should be used when operating this vehicle on
any side hill conditions. Effectiveness of brakes is significantly reduced on
hills. Some hills are too steep to safely stop or recover from an unsuccessful
climbing attempt. If vehicle slides backwards down hill, apply brakes with
gradual, even pressure and do not apply the throttle. Sudden or aggressive
application of brakes may cause loss of control.
REDUCE SPEED when operating this vehicle on rough or hilly terrain, or
when carrying cargo.
OFF-ROAD USE ONLY. Never operate on public roads as severe injury or
death may occur - this vehicle is not built for legal operation of public roads.
Always avoid paved surfaces.
NEVER OPERATE THIS VEHICLE AT EXCESSIVE SPEEDS. You in-
crease your risk of losing control if you operate this vehicle at speeds too fast
for the terrain, visibility conditions, or your experience.
HELMETS ARE RECOMMENDED WHENEVER DRIVING THIS VEHICLE
IN AN AGGRESSIVE MANNER. Eye protection is recommended at all
times. (See Owner’s Manual)
REVERSE OPERATION CAN BE DANGEROUS. Steering control becomes
difficult. When backing up, proceed slowly and apply brakes carefully;
aggressive braking may result in loss of control. Avoid backing downhill.
avoid turning at sharp angles in reverse.
STOPPING DISTANCE MAY INCREASE WITH WET BRAKES OR ON
WET SURFACES.
VEHICLE DESIGNED MAINLY FOR WARM WEATHER USE. Throttle link-
age and brakes may stick if operated in freezing weather, causing loss of
control. Dirt mud, water or other contaminants can also affect operation of
controls. Check both frequently.
High speeds, jumps and stunts are dangerous and could result in loss of
control and other accidents.
NEVER PERMIT A GUEST TO OPERATE THIS VEHICLE unless the guest
has read the Owner’s Manual and all labels.
NEVER USE ALCOHOL OR DRUGS before or while operating the vehicle.
They slow reaction time and impair judgement.
SEVERE INJURY OR DEATH can result if you do not follow these instruc-
tions.
CAUTION: Do not shift while vehicle is moving.

LABEL LOCATION
4
1 3 5
2
1. Warning (General)
2. Warning (Vehicle roll-over)
3. Warning (Load Distribution)
4. Warning (Cargo Bed)
5. Tire Pressure
6. Towing Information

DAILY PRE-RIDE INSPECTION
Inspect your vehicle each time before riding to ensure it is in proper working
order. If proper inspection is not done, severe injury or death could result.
WARNING
If a proper inspection is not performed serious injury or death can result.
Always inspect your RANGER before riding following the checklist care-
fully.
Before riding your vehicle, inspect all operating controls and parts.
Item/Inspection Procedure
1. Tires - check condition and pressures
2. Fuel and oil tanks - fill both tanks to their proper levels
3. All brakes - check operation, adjustment and fluid level (includes
emergency/parking brake)
4. Throttle - check for free operation and closing
5. Headlight/Taillight/Brakelight - check operation of all indicator lights
and switches
6. Engine ignition switch - check for proper function
7. Wheels - check for tightness of wheel nuts and axle nuts; check that
axle nuts are secured by cotter pins
8. Air cleaner element - check for dirt; clean or replace
9. Steering - check for free operation noting any unusual looseness in
any area
10. Loose parts - visually inspect vehicle for any damaged or loose nuts/
bolts or fasteners
11. Operator and passenger should be properly dressed.
12. Engine coolant - check for proper level at the recovery bottle.
13. Check condition and operation of the dump box/bed latch mecha-
nism.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
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 differ-
ent types of terrain.
Read and understand the Owner’s Manual and all warning and instruc-
tion labels on the vehicle.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
Use of this vehicle by a child can lead to severe injury or death of the child
or others.
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 judg-
ment needed to operate the vehicle safely and may be involved in a seri-
ous accident.
No one without a valid driver’s license should operate a Polaris RANGER.
10

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
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.
Always avoid operating the vehicle on any paved surfaces, including
sidewalks, driveways, parking lots and streets.
WARNING
Safe operation of this vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this
vehicle have an increased risk of overturns and loss of control which
could result in serious injury or death.
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
Never operate this vehicle on any public street, road or highway, in-
cluding dirt or gravel.
In many states it is illegal to operate vehicles of this type on public
streets, roads and highways.
11

OPERATION WARNINGS
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.
Never consume alcohol or drugs before or while driving this vehicle.
WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can
result in an accident.
Always travel at a speed which is proper for the terrain, visibility and
operating conditions; and your experience.
12

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
Always inspect your RANGER each time you use it to make sure it
is in safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
Never attempt stunts such as jumps. Don’t try to show off.
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes, without enough time
to react.
Could result in the vehicle overturning or going out of control.
Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
13

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slip-
pery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result in
an accident, including an overturn.
Do not operate on excessively rough, slippery or loose terrain until
you have learned and practiced the skills necessary to control the ve-
hicle on such terrain.
Always be especially cautious on these kinds of terrain.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills than on
level surfaces or small hills.
Never operate the RANGER on hills too steep for the vehicle or for your
abilities.
Practice on smaller hills before attempting large hills.
Never operate vehicle on hills steeper than 15.
14

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause vehicle to overturn.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly. The vehicle could go out of control.
Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the hill.
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Always check the terrain carefully before you start down any hill.
Never go down a hill at high speed.
Avoid going down a hill at an angle which would cause the vehicle to
lean sharply to one side. Go straight down the hill where possible.
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Avoid hills with excessively slippery or loose surfaces.
15

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause vehicle to overturn.
Before operating in a new area, check for obstacles.
Use extreme caution when riding over large obstacles, such as large rocks
or fallen trees.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
You may lose control of the vehicle.
You may also regain traction unexpectedly, which may cause the vehicle
to overturn.
On slippery surfaces, such as ice, go slowly and be very cautious in order
to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Riding on frozen lakes and rivers.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator break
through the ice.
Never ride your RANGER on a frozen body of water before you are sure
the ice is thick enough and sound enough to support the machine and its
operator, as well as the force that is created by a moving vehicle.
16

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which
could lead to an accident.
Never operate this vehicle in fast flowing water or in water deeper than
that specified in your Owner’s Manual. See page 52.
Remember that wet brakes may have reduced stopping ability. Test
your brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in serious injury.
Before you select reverse gear, make sure there are no obstacles or
people behind you. When it is safe to proceed, go slowly. Always avoid
backing down hill.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven
tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or operation of this vehicle with
improper or uneven tire pressure, may cause loss of control, and in-
creases the risk of an accident.
Always use the size and type tires specified in the Owner’s Manual for
this vehicle. See page 91.
Always maintain proper tire pressure as described in the Owner’s
Manual. See page 2.
17

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this vehicle may cause
changes in handling which in some situations could lead to an accident.
Never modify this vehicle through improper installation or use of accessories.
All parts and accessories added to this vehicle should be genuine Polaris In-
dustries Inc. or equivalent components designed for use on this vehicle; and
should be installed and used according to instructions. If you have questions,
consult an authorized Polaris dealer.
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards while climbing a hill.
WHAT CAN HAPPEN
Could result in vehicle overturning.
Maintain steady speed when climbing a hill.
If you lose all forward speed:
Apply the brakes.
Lock parking brake after you are stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brake gradually.
When fully stopped, lock parking brake.
In the event of an accident, have a qualified service dealer check the com-
plete machine including, but not limited to brakes, throttle and steering for
possible damage.
18

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Overloading this vehicle or carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
Never exceed the stated load capacity for this vehicle.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-
tance for braking.
Always follow the instructions in the Owner’s Manual for carrying cargo or
pulling a trailer. See page 45.
WARNING
Never carry passengers in the box.
If the weight distribution on the box is located toward the rear of the box
and the release lever is pulled forward, the box will want to dump on its
own. Never operate the dump lever without checking the position of
the load. This will prevent unexpected dumping of the cargo box.
WARNING
In the event of an accident have a qualified service dealer check the
complete machine including, but not limited to, brakes, throttle, and
steering for possible damage.
19

VEHICLE IDENTIFICATION NUMBERS
Important: Record these numbers from your vehicle in the spaces provided.
1. Frame VIN:
2. Vehicle Model Number:
3. Engine Serial Number (Right front side of engine crankcase)
Remove the spare key and store in a safe place. Record your ignition key num-
ber here. It is a four digit number found stamped on the key. In the event the
key is lost, replacement can be made by supplying your dealer with this number.
Ignition Key Number
The vehicle frame and engine serial numbers are important for model identifica-
tion when registering your vehicle, obtaining insurance or whenever replace-
ment parts are required. In the event your vehicle were stolen these numbers
are essential to the recovery and identification of your vehicle.
Dealer Imprint
20

CONTROL PARTS AND FUNCTIONS
Fuel Gauge
The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank.
When the red indicator needle comes near the E (empty) mark, refuel at the earliest
opportunity.
Ignition Switch
This 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 off except Acc. 12V.
ON All 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
position.
Do not operate the starter continuously for more than 5 seconds, or the start-
er will overheat and the battery power will drop temporarily. Wait at least 5 seconds
between each operation of the starter to let it cool and the batter power recover.
Do not turn the ignition switch key to the START position with the engine run-
ning, or damage to the starter can result.
Light Switch Lever
Turn on headlights and taillights by flipping the light switch lever up, with the ignition
switch key in the ON position.
The lights go off when the lever is pushed down.
4WD - AWD Rocker Switch
This vehicle can be operated in either 4WD or AWD. The 4WD-AWD is operated
by a rocker switch located on the console. Flipping the lever up will engage the
AWD.
21

Parking Brake Lever
The parking brake lever is located at the right side of the driver’s seat. Pull the lever
up and to the rear to apply the parking brake.
To release, push in and hold the knob on the end of the lever and push the lever
all the way down. Spring pressure helps return the lever to the released position.
Auxiliary Lighting/Electrical
Accessory Terminals
The auxiliary lighting/electrical ac-
cessory 12 volt terminals (1) are lo-
cated under the instrument panel.
An auxiliary light or other optional
light, or an accessory may be con-
nected to these terminals.
Brake Pedal
The brake pedal (2) is the left pedal
on the foot board. Depress the
brake pedal to slow or stop the ve- 1
hicle.
WARNING: Once a bottle of brake

fluid is opened, use what is neces-
sary and discard the rest. Do not
store or use a partial bottle of brake
fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture
from the air. This causes the boiling
temperature of the brake fluid to
drop, which can lead to early brake
fade and the possibility of serious in-
jury. 2
Braking
NOTE: Practice starting and stopping (using the brakes) until you are 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.
1. Release the throttle pedal completely
2. Press on the brake pedal evenly and firmly.
WARNING
Be sure to apply the parking brake before leaving the vehicle. If the vehicle
moves, it might be damaged or cause injury.
22

Seat Belts
The vehicle is equipped with lap-style seat belts for the operator and passenger.
WARNING
Seat belts reduce injury. Always were your seat belt. Minimum age recommen-
dation for passengers if five years old. Passengers under five years of age re-
quire special restraints which are not available with this vehicle.
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.
To unfasten the belt, press on the squared red button in the center of the buckle.
Steering Wheel
The steering wheel position can be
adjusted to suit the operator.
1. Loosen the bolt and nut (1) on the
steering column bracket and
move the steering wheel up or
down to desired height.
2. Tighten the bolts and nuts.
1
Throttle Pedal
The throttle pedal is the right pedal on the floor board. Push the pedal down to in-
crease 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. In addition, there must be adequate throttle pedal play. Refer to page 76
for throttle pedal adjustment procedure.
Trailer Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer tow-
ing equipment is not supplied with this vehicle.
To avoid injury and property damage, observe the precautions on page 45.
23

Engine Fuel
and Oil System
The fuel tank filler cap (1) is lo-
cated on the left side by the driv-
ers seat. Use either leaded or un-
leaded gasoline with a minimum
pump octane number of 87 R+
M/2 octane.
The fuel supply valve (2), located

in the center console storage
compartment (A) has three posi-
tions:
OFF: For vehicle storage and 1
whenever transporting.
ON: For normal operation.
RES: For reserve supply in the
event of main supply exhaustion.
NOTE: There is about a 7 to 10
mile (11.2 to 16 km) range on re-
serve gas. Always refill the gas
tank as soon as possible after
having used the reserve supply.
Always return valve to “on” posi-
tion after refueling machine.
Gasoline and Alcohol
Blends
Blends of gasoline and alcohol
called “gasohol” can be used on 2
an occasional basis, however
continued use is not recom-
mended. Switch back immedi-
ately to gasoline which does not
contain alcohol if you experience
any operating irregularities. Any
deterioration of fuel system com-
ponents or degradation of perfor-
mance resulting from the use of
gasohol will not be covered by
Polaris’ Warranty.
24

WARNING
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
Always refuel with the engine stopped and outdoors or in a well venti-
lated area.
Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
Do not over fill the tank. Do not fill the tank neck.
If you should get gasoline 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 pow-
ered engine exhaust fumes are poisonous and can cause loss of con-
sciousness and death in a short time.
Shut off fuel valve whenever the vehicle is stored or parked.
25

WARNING
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.
Never use gasohol with an octane rating lower than the minimum octane rat-
ing specified for this product.
Never use gasohol containing more than 10% ethanol (grain alcohol).
Never use gasohol containing more than 5% methanol (wood alcohol). Gas-
oline containing methanol must also be blended with cosolvents and corrosion in-
hibitors.
Never use gasohol for extended periods and never store this vehicle with
gasohol in the fuel system.
Gasoline containing alcohol can cause paint damage. Be extra careful not
to spill gasohol during refueling.
26

CONTROL AND PARTS FUNCTIONS
VEHICLE NOMENCLATURE - Left View
1
7
3 4
6
9
10
11 8
1. Cab Frame
2. Cab Frame Hand Hold
3. Dashboard
4. Steering Wheel
5. Gear Shift Lever
6. Seat
7. Cargo Box
8. Seat Belts
9. Parking Brake
10. Engine Compartment Access Panel
11. Hood Latches (attached to hood; left and right sides under dash)
27

VEHICLE NOMENCLATURE - Front View
13
14
12 12
16 15
12. Headlights
13. Air Box (under hood)
14. Battery (under hood)
15. Radiator (under hood)
16. Front Bumper/Brush Guard
28

VEHICLE NOMENCLATURE - Rear View
17
17
18
21
20 19
17. Tail Gate Latches (Top and Bottom)

18. Tail Gate
19. Muffler (Spark Arrester)
20. Trailer Hitch Receiver
21. Taillight
29

VEHICLE NOMENCLATURE - Instrument Panel
4
3 6
5
7
8
9
2
12 11
1 10
1. Choke Knob
2. Ignition Switch
3. Hour Meter
4. Passenger Warning Decal
5. Neutral Indicator Light
6. Reverse Indicator Light
7. Brake Light
8. Coolant Temperature Warning Light
9. Fuel Gauge
10. 12V Accessory Plug
11. Fog/High Beam Light Switch
12. AWD (All Wheel Drive) Switch
30

Demand 6 Drive
Exclusive Demand 6 Drive System (All Wheel Drive)

This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 6 Drive
(AWD) system which is activated by a switch on the dash. When the switch is “off”
the RANGER is in 4 wheel drive at all times. When the switch is “on” the RANGER
is in Demand 6 Drive and the front wheels will automatically engage anytime the
rear wheels lose traction. When the rear wheels regain traction, the front wheels
will automatically disengage.
The AWD button position and a red AWD light indicates when the vehicle is in De-
mand 6 Drive. There is no limit to the length of time the vehicle may remain in De-
mand 6 Drive.
The AWD switch may be turned on or off while the vehicle is moving. If the switch
is turned off when the front hubs are driving they will not release until the rear
wheels regain traction.
CAUTION: Do not switch on Demand 6 Drive if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage. Engage the Demand 6 Drive
switch before getting into conditions where front wheel drive may be needed. If the
rear wheels are spinning, release the throttle before turning the Demand 6 Drive
switch on.
31

Transmission Gear Selector Operation
The transmission gear selector is located to
the right of the vehicle driver’s seat. The
transmission selector lever has four posi- Shift Pattern
tions: high forward (D2); reverse; neutral;
and low forward (D1).
Use of (low forward gear - D1) is recom- D-2 D-1
mended in heavy pulling situations to extend
belt life.
To change gears, stop the vehicle and with N
the engine idling, move the lever to the de-
sired gear. Do not attempt to shift gears
with engine speed above idle or while the R
vehicle is moving.
Always place the transmission in gear with the parking brake locked whenever the
vehicle is left unattended.
Maintaining shift linkage adjustment is important to assure proper transmission
function. Should you experience any shifting problem see your dealer.
WARNING
1. Do not attempt to shift the transmission while the vehicle
is moving or while operating on hilly terrain.
2. Always place the transmission in gear with the parking
brake applied and turn the vehicle off whenever the ve-
hicle is left unattended.
32

Disengaging Wheel Hubs
When backing uphill while in Demand 6 Drive and then going forward downhill, one
or both hubs may remain engaged. If one or both hubs remain engaged they can
be disengaged by stopping, shifting to and moving in reverse. Then proceed in
forward again.
You can tell if only one front hub is engaged if the steering pulls to one side. If both
front wheel hubs are engaged, steering effort increases but remains balanced from
left to right, and vehicle speed is somewhat restricted.
WARNING: If both hubs were engaged and only one released during opera-
tion, loss of control could result. If you experience hub engaging symptoms, use
the above disengaging technique before proceeding. Failure to disengage front
hubs as directed above could result in severe injury or death.
If the hubs remain engaged after following these instructions return the vehicle to
your dealer for service.
PVT System
WARNING
The PVT system rotates at high speeds, creating large amounts of force
on clutch components. Extensive engineering and testing has been con-
ducted to insure the safety of this product. However, as the owner you
have the following responsibilities to make sure this system remains safe:
Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at high speeds. This
system has been precision balanced. Any modification will cause the
system to be out of balance, creating vibration and additional loads
on components.
Routine maintenance is the responsibility of the owner. Always fol-
low recommended maintenance procedures. See your dealer!
This PVT system is intended for use on Polaris products only.
The PVT housing must be securely in place during operation.
Failure to comply with this warning can result in severe injury or death.
33

Engine Cooling System
Coolant Level
The recovery bottle (1), located
on the left side of the machine
must be maintained between the
minimum and maximum levels
indicated on the recovery bottle.
The engine coolant level is con-
trolled or maintained by the re-
covery system. The recovery
system components are the re-
covery bottle, radiator filler neck,
radiator pressure cap and con-
necting hose.
1
As coolant operating tempera-
ture increases, the expanding
(heated) excess coolant is forced out of the radiator past the pressure cap and into
the recovery 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 machines is normal as the system is purg-
ing itself of trapped air. Observe coolant levels and maintain as recommended by
adding coolant to the recovery bottle. Polaris recommends the use of Polaris Pre-
mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com-
patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is
already premixed and ready to use. Do not dilute with water. NOTE: Always follow
the manufacturer’s mixing recommendations for the freeze protection required in
your area.
34

Radiator Coolant Level Inspection
NOTE: This procedure is only required if the cooling system has been drained for
maintenance and/or repair. However, if the recovery bottle has run dry, the level
in the radiator should be inspected and coolant added if necessary.
WARNING Never remove the pressure cap when the engine is warm or hot.
Escaping steam can cause severe burns. The engine must be cool before remov-
ing the pressure cap.
Lift the hood and locate the radiator cap.
NOTE: Use of a non-standard pressure cap will not allow the recovery system to
function properly. If the cap should need replacement contact your dealer for the
correct replacement part.
Drain Plug
Locations
Crankcase Drain
The oil should be changed annu-
ally, especially before off season
storage. If the machine is used
in wet conditions the oil should
be checked more frequently. If
the oil has a milky appearance it
should be changed as soon as
possible. Failure to properly
maintain this important area can
result in premature wear or pos-
sible failure of the engine com-
ponents. Always use Polaris Recoil
0W-40 oil. Drain
Engine Access
Panel Removal and
Installation
2
Engine access panels are re-
moved by pulling handle out and
then up (no tools are required). 1
Install by firmly placing the bot-
tom pins in the grommets and
pushing the top pins (1) into the
grommets (2).
35

To insure that the coolant maintains its ability to protect the engine, it is recom-
mended that the system be completely drained every two years and a fresh mixture
of antifreeze and water be added. Polaris recommends the use of Polaris Pre-
mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com-
patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is
already premixed and ready to use. Do not dilute with water. IMPORTANT: Al-
ways follow the manufacturer’s mixing recommendations for the freeze protection
required in your area.
Using a funnel, slowly add coolant as necessary.
36

4 Cycle Premium 4 Synthetic Lubricant
Polaris Premium 4 All Season Synthetic engine oil has been specially formulated
for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis-
cosity oil designed to provide the ultimate in lubrication performance and protec-
tion.
Premium 4 possesses unsurpassed film strength over the widest possible temper-
ature 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. Oil may need to be changed more fre-
quently if Polaris Premium 4 is not used. You will also need to follow the manufac-
turers recommendations for ambient temperature operation.
Oil System
The oil tank is located on the left side of the vehicle. To check the oil:
1. Set machine on a level surface.
2. Start the engine and let it
idle for 20-30 seconds.
3. Stop the engine, remove
dipstick (1) and wipe dry
with a clean cloth.
4. Screw in the dipstick
completely, remove it and
read the oil level. NOTE:
The dipstick must be
screwed in to keep the
angle and depth of stick
consistent.
5. Remove dipstick and check 2
to see that the oil level is
between the full and add
marks. Add oil as indicated
by the level on the dipstick.
Do not overfill.
CAUTION: Use only Polaris ADD 8 OZ. NORMAL FULL
Premium 4 All Season synthetic
oil (PN 2871271), or API certified
“SH” oil. Never substitute or mix Maintain Oil Level In Normal Range
oil brands. Serious engine dam-
age and voiding of warranty can
result.
37

Oil and Filter Change
The recommended oil change interval is 100 hours, 1000 miles, or every six
months, whichever comes first. Suggested break in oil change is at 20 hours, 500
miles, or one month, whichever comes first. Severe use operation requires more
frequent service. Severe use includes continuous duty in dusty or wet conditions,
and cold weather riding. NOTE: Severe use cold weather riding is all riding below
10° F, and riding between 10° F and 30°F when most trips are slow speed and less
than 5 miles. Be sure to change the oil filter whenever changing oil (Polaris PN
3084963).
1. Place vehicle on a level
surface.
2. Remove rear wheel well
panel by cutting dart clips
and removing screws.
3. Clean area around drain
plug at the bottom of the oil
tank.
4. Run engine for two to three
minutes until warm. Shut
engine off.
5. Place a drain pan beneath
the oil tank and remove the 2
drain plug. CAUTION: Oil
may be hot. Do not allow hot 1
oil to come into contact with
skin as serious burns may
result.
6. Allow oil to drain completely.
7. Install a new sealing washer (PN 5850135) on oil drain plug. NOTE: The
sealing surfaces on the drain plug and the oil tank should be clean and free of
burrs, nicks or scratches.
8. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)
9. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter (1)
counterclockwise to remove.
10. Using a clean dry cloth, clean filter sealing surface on crankcase.
11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make
sure the O-Ring is in good condition. Also make sure the O-ring from the old
filter is not still on the engine.
12. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket contact.
13. Approximately 1 cup of engine oil will remain in the crankcase. To drain,
remove drain plug found on lower right side of crankcase. NOTE: The sealing
surfaces on the drain plug and crankcase should be clean and free of burrs,
nicks or scratches.
38

Oil and Filter Change (Cont.)
14. Reinstall drain plug.
15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.
Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts
initially.
16. Place gear selector in neutral and set parking brake.
17. Start engine and let it idle for one to two minutes. Stop engine and inspect for
leaks.
18. Re-check oil level on the dipstick and add oil as necessary to bring the level to
the upper mark on the dipstick.
19. Dispose of used filter and oil properly.
Fuel Filter and Oil Filter
Your Polaris RANGER is equipped with a unique in-line fuel filter.
These filters should be replaced by your dealer after every 100 hours of operation
or annually. Do not attempt to clean these filters.
39

STARTING THE ENGINE
Stopping the Engine
1. Release the throttle pedal completely.
2. Put the gear shift lever into (N) Neutral.
3. Apply the parking brake to help prevent the vehicle from rolling.
4. Turn the ignition switch key to the OFF position.
Procedure for Starting a Cold Engine
WARNING
Do not start or operate this vehicle with sticking or improperly operating
throttle pedal. A stuck or improperly operating throttle could cause an ac-
cident resulting in severe injury or death.
Always contact your dealer for service repairs whenever throttle prob-
lems arise.
Failure to check or maintain proper operation of the throttle system can
result in the throttle pedal sticking during driving and cause an accident.
Always check the pedal for free movement and return before starting the
engine and occasionally during driving.
1. Place the transmission in neutral and move the vehicle to a level surface.
2. Lock the parking brake.
3. Turn the fuel tank valve to ON.
4. Sit in the vehicle in the driver’s seat.
“FULL”
“HALF”
“OFF”
Choke Lever Side View
5. Move the choke lever to the FULL position.

6. Turn the ignition key to START.
40

STARTING THE ENGINE
7. If engine does not start, release ignition switch and wait five seconds; then turn
the ignition switch to start for another five seconds. Repeat this procedure until
engine starts.
NOTE: Do not press the throttle pedal while starting the engine.
After the Engine Starts
1. If the engine slows or stops, use of the choke lever at its HALF position will allow
proper engine warm up.
2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine
idles smoothly. Then move the choke to OFF.
CAUTION: Proper engine warm up is essential each time before driving to avoid
engine damage.
WARNING
Carbon monoxide exhaust gas is poisonous!
Always start the vehicle outdoors.
Never run the engine in an enclosed area.
41

STARTING THE ENGINE
Procedure for Starting a Warm Engine
Warm engines do not normally require the use of the choke since the spark plug
can easily become wet fouled.
1. Place the transmission in neutral and move the vehicle to a level surface.
2. Lock the parking brake
3. Turn the fuel tank valve to ON.
4. Sit in the vehicle in the driver’s seat.
5. Turn the ignition key to START.
“HALF”
“OFF”
Choke Lever Side View
6. If the engine has cooled to a point where it does not readily start, intermittent
use of the choke lever in its HALF position is permitted.
7. If the engine is over-choked by mistake when warm, depress the throttle lever
fully while cranking to aid in starting.
8. Release the throttle lever immediately after the engine starts. If the engine does
not start and all conditions are favorable, change the spark plug.
42

STARTING THE ENGINE
Recoil Starter
Recoil Starter
If the battery is weak and cannot start the engine, use of the recoil starter located
on the right side of the machine will allow vehicle operation until repairs can be
made.
1. Be certain the parking brake is set. See page 27.
2. Remove right side engine access panel. See page 35.
3. Grasp the recoil starter tightly and pull slightly until the starter mechanism en-
gages.
4. Pull the rope abruptly to start the engine. CAUTION: Take care not to extend
the starter rope so far that it stops, causing damage to the recoil assembly.
CAUTION: Never start the engine with the battery disconnected. Damage to the
electrical system and lamps may result.
43

VEHICLE BREAK-IN PERIOD
The break in period for your new Polaris RANGER is defined as 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 treat-
ment of a new engine will result in more efficient performance and longer life for the
engine. Perform the following procedures carefully.
CAUTION: Use only Polaris Premium 4 All Season synthetic oil, or API certified
“SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding
of warranty can result.
1. Fill fuel tank with either unleaded or leaded fuel which has a minimum pump
octane number of 87= (R+ M)/2.
2. Check oil reservoir level in-

dicated on dipstick. Add oil
if necessary.
3. Drive slowly at first. Select ADD 8 OZ. NORMAL FULL

an area which is open and
will give you room to famil-
iarize yourself with vehicle Maintain Oil Level In Normal Range
operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle. CAUTION: Do

not operate at full throttle or high speeds for extended periods during the first
three hours of use. Excessive heat can build up and cause damage to close
fitted engine parts.
5. Perform regular checks on fluid levels, controls and all important areas on the
vehicle as outlined earlier on the daily pre-ride inspection checklist found on
page 9.
6. Pull only light loads.
7. Break in oil and filter. Change at 20 hours or 500 miles.
44

CARRYING LOADS
The RANGER has been designed to carry or tow a certain amount of load. Always
read and understand the load distribution warnings listed on the warning labels.
Never exceed the following weights.
Maximum Capacities Cargo Box
(Level Ground)
RANGER - 1500 lbs. (681 kg) 1000 lbs. (454 kg)
Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload
the vehicle while parked on an incline.
2. Set the parking brake.
3. Dismount the vehicle.
4. Stand clear and pull the cargo box release mechanism lever forward. Lift the
front of the cargo box to dump.
Maximum Towing Capacities (Level Ground)
Maximum towed load weight - 1500 lbs. (681 kg) on level ground only; 850 lbs. (386
kg) up to 15° grade. Maximum vertical hitch weight - 150 lbs (68.1 kg).
Use of low forward is recommended in heavy pulling situations to extend belt life.
Maximum grade while trailer towing - 15°; do not tow any trailer on a grade steeper
than 15°.
Total Towed Total Towed Total Hitch Towing
Load Weight Load Weight (15° Vertical Weight Speed
(level ground) grade)
1500 lbs. (681 kg) 850 lbs. (386 kg) 150 lbs (68.1 kg) 10 mph (16 kph) or less
Do not carry more than 1000 Lbs. (454 kg) in the cargo box.
WARNING
Never carry a passenger in a trailer
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. Remem-
ber that towing a trailer increases braking distance.
Do not tow more than 1500 lb (681 kg) trailer weight(trailer plus cargo weight).
Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any oth-
er location or you may lose control of the vehicle and have an accident.
45

OPERATING SAFETY
Load Distribution
1. Always load the cargo box placing the load as far forward as possible.
2. Always operate the vehicle with extreme care whenever hauling or towing
loads.
3. Slow down and drive in D-1 only.
4. The cargo box dump latch must be securely latched before loading and operat-
ing. Unintentional box tilting will result if weight is placed in the rear of the box
and the latch is not secured.
WARNING: Never operate this vehicle with the cargo box in the raised position.
The cargo box could close unexpectedly while driving, severely injuring the driver.
The rear tires will catch the rear of the box, damaging the vehicle and creating haz-
ardous driving conditions.
Do not carry more than 1000 Lbs. in the cargo box.
Parking the RANGER

1. Stop the vehicle on a level surface.
CAUTION: Avoid parking on steeply inclined surfaces.
2. When the engine has stopped, apply the parking brake to help prevent the ve-
hicle from rolling
WARNING
Be sure to apply the parking brake before leaving the vehicle. If the vehicle
should move, it might be damaged or cause injury.
3. Remove the ignition switch key to prevent unauthorized use.

NOTE: When parking inside a garage or other structure, be sure the structure is
well ventilated and the vehicle is not close to any source of flame or sparks. This
includes any appliance with a pilot light.
WARNING
Gasoline is extremely flammable and can be explosive under certain condi-
tions.
46

OPERATING SAFETY
1. Sit in the driver’s seat with the seatbelt fastened.
2. After starting the engine and allowing it to warm up, shift the transmission into
gear.
3. Check your surroundings and determine your path of travel.
4. Release the parking brake.
5. Keeping both hands on the steering wheel, slowly depress the throttle with your
right foot and begin driving. Vehicle speed is controlled by the amount of
throttle opening and PVT shifting is done automatically.
6. Drive slowly, practice maneuvering and using the throttle and brakes on level
surfaces.

Load Distribution
WARNING
When carrying cargo or towing a trailer, remember that load weight will in-
crease braking distances. Failure to allow for increased braking distance
may result in accident and injury.
1. Always load the cargo bed placing the load as far forward as possible.
2. Always operate the vehicle with extreme care, especially when hauling or tow-
ing loads.
3. Slow down and drive in D-1 Gear only.
4. The cargo box dump latch must be securely latched before loading and operat-
ing. Unintentional box tilting can result if weight is placed in the rear of the box
and the latch is not secured.
5. Do not place loads on the cab frame
WARNING: Never operate this vehicle with the cargo box in the raised position.
The cargo box could close unexpectedly while driving, severely injuring the driver
or passenger. The rear tires can catch the rear of the box, damaging the vehicle
and creating hazardous driving conditions.
47

OPERATING SAFETY
Riding On Slippery Surfaces
Whenever driving on slippery surfaces such as wet trails or loose
gravel, or during cold freezing weather, special attention must be
paid to prevent vehicle turnover. Always:
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. Driving with Demand 6 Drive (All Wheel Drive) engaged can assist in control-
ling the vehicle in slippery areas. CAUTION: Never engage Demand Drive
while wheels are spinning as severe damage to drive train may occur.
Before operating your vehicle on a frozen body of water be sure that the ice is thick
enough to support the machine and its operator, as well as the force that is created
by a moving vehicle. Severe injury or death can result if the vehicle and/or its oper-
ator break through the ice.
WARNING
Failure to exercise care when operating on slippery surfaces can be dan-
gerous.
Loss of tire traction and vehicle control can result in an accident, including
an overturn.
Never apply brakes during a skid. Complete loss of control can result.
Do not operate on excessively slippery surfaces if possible.
Always reduce speed and use additional caution.
48

OPERATING SAFETY
Operating on Hills
WARNING
Improperly crossing hills or turning on hills can be dangerous!
Loss of vehicle control or overturning of the vehicle could occur.
Avoid crossing the side of a steep hill if possible.
Use extreme care when operating your RANGER in hilly terrain.
Whenever descending a hill always:

1. Drive directly downhill.
2. Slow down.
3. Apply the brakes lightly to aid in slowing.
WARNING
Loss of vehicle control due to excessive speed can occur. Loss of control
may result in serious injury or death.
Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills.
2. Keep both feet on the footrests.
3. Proceed at a steady rate of speed and throttle opening.
49

OPERATING SAFETY

WARNING
Braking and handling are greatly affected whenever operating in hilly ter-
rain.
Loss of vehicle control or overturning of the vehicle could occur.
Avoid climbing steep hills (15 maximum).
Use extreme care when operating your vehicle in hilly terrain.
WARNING
Avoid climbing steep hills.
Loss of vehicle control or overturning of vehicle could occur.
Use extreme care when operating your RANGER in hilly terrain.
WARNING
Improperly crossing hills or turning on hills could cause loss of control or
cause the vehicle to overturn.
If at all possible, avoid crossing the side of a steep hill. Avoid hills with ex-
cessively slippery or loose surfaces.
50

OPERATING SAFETY
WARNING
Going down a hill improperly could cause loss of control or cause the ve-
hicle to overturn.
Always check the terrain carefully before you start down any hill.
Never go down a hill at high speed.
Avoid going down a hill at an angle which would cause the vehicle to lean
sharply to one side. Go straight down the hill where possible.
WARNING
Climbing hills improperly can cause loss of control or cause vehicle to over-
turn.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly. The vehicle could go out of control.
Never go over the top of any hill at high speed. An obstacle, a sharp drop,
or another vehicle or person could be on the other side of the hill.
51

OPERATING SAFETY
Crossing Streams
Your Polaris RANGER can operate through water up to depths reaching the floor-
boards. Before fording streams always:
1. Determine water depths and current.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to the lever until brak-
ing action is normal.
Should your vehicle become immersed, it will be necessary to take it to your dealer
as soon as possible. Do not start the engine! Immersion of the vehicle can cause
major damage if not correctly repaired.
WARNING
Never try to cross any deep or fast flowing streams.
The large tires can cause the vehicle to float resulting in loss of control.
Determine stream depth and speed before crossing.
52

OPERATING SAFETY
Trail Obstacles
Keep Alert!
Look ahead and learn to read the trail as you ride. Stay on the right side of the trail,
if possible, and be constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Hidden or unseen hazards on the trail can be dangerous.
Personal injury or the vehicle overturning can occur from unseen obstacles.
Keep alert and constantly look for obstacles on the trail.

53

OPERATING SAFETY
Backing Up
1. When backing up, always avoid backing downhill.
2. Back slowly.
3. When in reverse, apply the brakes lightly for stopping.
4. Avoid turning at sharp angles in reverse.
5. Never open the throttle suddenly while backing.
6. Always inspect left and right fields of vision before backing.
WARNING
Backing your RANGER can be dangerous! You could hit an obstacle or
person behind you; or the vehicle could tip over on a steep incline.
Always back slowly, avoiding excessive speed.
Avoid backing on steep inclines.
Parking On An Incline
Whenever the Vehicle is Parked
1. Place the transmission in gear.
3. Avoid parking on an incline. If it is necessary to park on an incline, always block
the rear wheels on the down hill side.
4. Shut off fuel supply.
WARNING
Always check to be sure that the parking brake has been disengaged
before operating the vehicle. An accident could result if the parking
brake is left on while the vehicle is operated.
Always block the downhill side of the wheels if leaving the vehicle on
a hill or park the vehicle in a side hill position.
54

OPERATING SAFETY
Dumping the Cargo Box
1. Select a level site to dump the
cargo box. Do not attempt to
dump or unload the vehicle
while parked on an incline.
3. Dismount the vehicle.
4. Stand clear and pull the cargo
box release mechanism lever
(1) forward. Lift the front of
the cargo box to dump.
1
WARNING
If the weight distribution on the box is located toward the rear of the box
and the release lever is pulled forward, the box will want to dump on its
own. Never operate the dump lever without checking the position of
the load. This will prevent unexpected dumping of the cargo box.
WARNING
Never carry passengers in the box.
WARNING
In the event of an accident have a qualified service dealer check the
complete machine including, but not limited to, brakes, throttle, and
steering for possible damage.
55

NOISE EMISSION CONTROL SYSTEM REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!
U.S. Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any person other than for purposes of
maintenance, repair, or replacement of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise control prior to its sale or delivery
to the ultimate purchaser or while it is in use or
(2) the use of the vehicle after such device or element of design has been removed
or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE
ACTS LISTED BELOW.”
1. Removal or alteration or the puncturing of the muffler or any engine component
which conducts removal of engine exhaust gases.
2. Removal or alteration or the puncturing of any part of the engine air induction
system.
3. Replacement of any vehicle parts with parts not in compliance with federal reg-
ulations.
4. Lack of proper maintenance.
CAUTION: Remember, exhaust system components are very hot during and after
use of the vehicle.
Do not touch hot exhaust system components. Serious burns can result.
Be especially careful when traveling through tall grass. The potential for fire
exists.
USFS Approved Spark Arrestor
The muffler on this vehicle was tested and approved in accordance with the USFS
Forest Service Standard 5100-1A.
56

BATTERY
Battery
CAUTION
Whenever removing the battery, discon-
nect the negative (black) cable first. When
reinstalling the battery, connect the nega-
tive (black) cable last.
Maintain
Replenishing the Battery Fluid
between
A poorly maintained battery will deteriorate upper and
rapidly. Check the battery fluid level often. lower level
The fluid level should be kept between the marks
upper and lower level marks.
To refill use only distilled water. Tap

water contains minerals which are harmful
to a battery.
Battery Connections
Battery terminals and connections should be kept 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 rags. Coat the terminals with dielectric grease or petro-
leum jelly.
Do not allow cleaning solution or tap water to enter the battery. It will shorten
the life of the battery.
Vehicle lamps may burn out if battery is disconnected during vehicle opera-
tion. Also, the reverse speed limiter can be damaged.
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 magne-
sia, 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.
57

BATTERY
Battery Removal
1. Disconnect hold down straps
holding the battery (1) in position 1
and remove battery retainer.
2. Remove the battery vent tube
from the battery.
3. Disconnect the black (negative)
battery cable first.
4. Disconnect the red (positive) bat-
tery 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 table-
spoon baking soda and one cup water to prevent damage to the RANGER.
Battery Installation
WARNING: To avoid the possibility of explosion, always connect battery cables
in the order specified. Red (positive) cable first; black (negative) cable last.
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, 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.
6. Reinstall battery cover and attach the hold down strap.
NOTE:
When your RANGER is placed in storage for three months or more, the battery
should be removed, charged to proper level, and stored in a cool dry place.
Before reusing, take the battery to your dealer for testing and recharging.
58

MAINTENANCE
Periodic Maintenance Schedule
Careful periodic maintenance will help keep your vehicle in the safest, most reliable
condition. Inspection, adjustment and lubrication intervals of important compo-
nents are explained in the following chart:
Maintenance intervals are based upon average riding conditions and a vehicle
speed of approximately 10 miles per hour. Vehicles subjected to severe use, such
as operation in wet or dusty areas, should be inspected and serviced more fre-
quently. If you are not familiar with safe service and adjustment procedures, have
a qualified dealer perform these operations.
Inspect, clean, lubricate, adjust or replace parts as necessary.
CAUTION: Due to the nature of these adjustments, it is recommended that
service be performed by an authorized Polaris dealer. Do not attempt to perform
this work unless you are familiar with mechanical repair.
More often under severe use, such as dirty or wet conditions
Emission Control System Service (California)
NOTE: Inspection may reveal the need for replacement parts. Always use genu-
ine Polaris parts available from your Polaris dealer.
Item Hours or Frequency Remarks
Odometer
Engine Oil - Level/Change 100 hrs/1000 6 months Check Level Daily; Break in Service at
(4-Cycle) miles 1 month. Change oil more often in cold
weather use.
Oil Filter 100 hrs/1000 6 months Replace with oil change

miles
Engine breather filter 20 hrs Monthly Inspect–replace annually and as need-

ed
Engine breather hose 100 hrs 6 months Inspect
Engine Mounts 100 hrs 12 months Inspect
Engine Cylinder Head and 25 hrs 3 months Inspect (re-torque required at first ser-
Cylinder Base Fasteners vice only)
Air Filter - Main Element Weekly Weekly Inspect-Replace if necessary
Valve Clearance 100 hrs 12 months Inspect/Adjust
Spark Plug 100 hrs 12 months Inspect–replace if necessary
Ignition Timing 100 hrs 12 months Inspect and adjust as needed
59

MAINTENANCE
Periodic Maintenance Schedule (Cont.)
Odometer
Fuel System 100 hours 12 months Check for leaks at fuel cap, lines, fuel
valve, filter, pump and carburetor. Re-
place lines every two years.
Fuel Filter 100 hrs 12 months Replace annually
Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to stor-
age
Idle Speed As Required As Required Adjust
Throttle Cable 50 hrs 6 months Inspect–adjust, lubricate, replace if nec-

essary; pre-ride inspection item
Choke (Enricher) Cable 50 hrs 6 months Inspect–adjust, lubricate, replace if nec-

essary
Coolant/Level Inspection Daily Daily Replace engine coolant every two

years
Coolant strength/pressure test 100 hrs 6 months Inspect strength seasonally; pressure
system test system annually
Radiator 50 hrs 12 months Inspect/clean external surface
Cooling System hoses 100 hrs 12 months Inspect
Spark arrestor 100 hrs 12 months Clean out
Recoil housing As required As required Drain moisture out after driving in water
General Lubrication 30 hrs 3 months Lubricate all fittings, pivots, cables, etc.
Front hubs/fluid check (AWD) 50 hrs 6 months Check monthly
Front hubs/fluid change (AWD) 100 hrs 12 months
Front Gearcase Oil 100 hrs 12 months Check monthly and change annually
Transmission Oil Level 25 hrs Monthly Inspect monthly; change annually
Shift linkage 50 hrs 6 months Inspect, adjust
Shift selector box 200 hrs 24 months Change lubricant every two years
Drive belt 50 hrs 6 months Inspect–adjust, replace if necessary
Clutches (drive and driven) 100 hrs 12 months Inspect, clean
Steering 50 hrs 6 months Inspect daily, lubricate
Toe adjustment As required As required Periodic inspection, adjust when parts

are replaced
Front Suspension 50 hrs 6 months Inspect–lubricate, tighten fasteners
Rear Suspension 50 hrs 6 months Inspect, tighten fasteners
Front wheel bearings 300 hrs 36 months Replace
Battery 20 hrs monthly Check Terminals/clean/check fluid level
Headlight Aim As required As required Adjust if necessary
60

MAINTENANCE
Periodic Maintenance Schedule (Cont.)
Odometer
Headlamp Inspection Daily Daily Check operation daily; apply Polaris di-
electric grease to connector when re-
placed
Tail lamp inspection Daily Daily Check operation daily; apply Polaris di-
electric grease to socket when replaced
Brake System Pre-ride Pre-ride Pre-ride inspection item
Brake fluid 200 hrs 24 months Change every two years
Brake pad wear 10 hrs/100 Monthly Inspect periodically

miles
Parking Brake Pre-Ride Pre-Ride Check lever adjustment daily; adjust
Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item
Wheels Pre-ride Pre-ride Pre-ride inspection item
Frame nuts, bolts, fasteners Pre-ride Pre-ride Pre-ride inspection item
CAUTION: Due to the nature of these adjustments, it is recommended that

service be performed by an authorized Polaris dealer. Do not attempt to perform
this work unless you are familiar with mechanical repair.
More often under severe use, such as dirty or wet conditions
Emission Control System Service (California - 4-Cycle)
61

MAINTENANCE
Lubrication Recommendations
Item Lube Rec. Method Frequency*
1.Engine Oil Polaris Pre- Add to proper level on dipstick. Check level dai-
mium 4 Syn- See page 37. ly.
thetic 0W40
2. Brake Fluid DOT 3 Only Maintain level between fill lines. As required;
See page 78. change every
two years or 200
hours
3. Transmission Polaris Pre- Add to FULL level on dipstick. Change annually
Oil mium Syn- See page 66. or at 100 hours
thetic chain
case lube
4. Front Gear- GL5 80-90 Fill to bottom thread of filler hole. Change annually
case Oil Weight Gear Make certain machine is on level
Lube surface.
5. Center Half- Grease+ Locate Fittings and Grease Every 3 months
shafts or 50 hours
6. Front Prop Grease+ Locate Fittings and Grease Every 3 months
Shaft U-joints or 50 hours
7. Front Prop- Grease+ Locate fittings and grease – 3 Every 3 months
shaft Yoke pumps maximum or 50 hours
Premium Remove set screw in hubs. Ro- Annually or at
8. Demand 6
Hub Lube tate wheels to 4 O’clock position. 100 hrs
Hubs - All
If lubricant is not visible add more.
Wheel Drive
Reinstall set screw.
9. Front Drive Grease+ Locate grease fitting and grease Every 3 months
Axle (U Joint) with grease gun. or 50 hours
10. Ball Joint Grease** Locate fitting on back side of Every 3 months
struts and grease with grease or 50 hours
gun.
62

MAINTENANCE
4. Front Gear Case
3. Transmission
Full
Operating Fill plug
Range
6. Front Prop Shaft
(U-Joint)
7. Propshaft Yoke
5. Center Halfshaft
(U Joint)
9. Axle Cardan
Front Drive
(AWD Models)
8. Demand Hubs
Upper
11. Front A-Arm
Pivot Shaft
8. 4 O’clock
position
10. Ball Joint
63

MAINTENANCE
11. Front A Arm Grease**∆ Locate fitting on pivot shaft and Every 3
Pivot Shaft grease with grease gun. months or 50
hours
12. Swing Arm Grease** Locate fittings on swing arm and Monthly or at
Bushings grease with grease gun. 20 hours
13. Upper Control Grease**∆ Locate fittings and grease Semi-annually
Arms
14. Lower Control Grease**∆ Locate fittings and grease Semi-annually
Arms
15. Center Wheel Grease**∆ Locate fitting and grease Semi-annually
Hub Bearing Car-
rier
16. Tail Shaft Grease**∆ Locate Fitting and grease Monthly or at
Coupler 20 hours
17. Center and GL5 80-90 Fill to bottom thread of filler hole. Monthly or at
rear angle drives weight Make certain machine is on a level 20 hours
gear lube surface.
* More often under severe use, such as wet or dusty conditions.
**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as
Conoco Superlube M or Mobilegrease Special.
+ Grease every 500 miles, or after submerging in water or before long periods of storage or
after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of
these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).
∆ When suspension action becomes stiff or after washing.
NOTE: Hours are based on 10 mph average.
64

MAINTENANCE
13. Upper Control

Arm
16.
17.
65

MAINTENANCE
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine
oil will cause accelerated wear and may result in engine seizure, acci-
dent, and injury.
Engine Oil
In order for the engine to function
properly, maintain the engine oil at the
proper level, and change the oil and
oil filter in accordance with the Period-
ic Maintenance Schedule. Not only
do dirt and metal particles collect in
the oil, but the oil itself loses its lubrica-
tive quality if used too long.
The transmission cover/dipstick (1) is 1
located on the right side of the ma-
chine inside the chassis.
2
Transmission Oil
The transmission lubricant level
should be checked monthly (or 1000
miles (1600 km), whichever comes
first. Transmission oil should be
changed annually.
To check the transmission lubricant
level you must first position the ve-
hicle on a level surface. Remove the
right engine access panel as de-
scribed on page 35. Reach inside the
engine compartment in the direction
indicated by the arrow (2). Remove fill
plug dipstick (3) by pulling upward and
check the lubricant level. Lubricant
A
should be kept at the full mark on the 3
dipstick. The correct transmission lu-
bricant to use is Polaris Premium Syn-
thetic Gearcase Lubricant (PN
2871478).
66

MAINTENANCE
Transmission Oil Changing
Procedure
1. Locate and remove fill plug/
dipstick.
2. Remove transmission drain
plug located on the bottom
right hand side and drain the
oil. Catch and discard used oil
properly.
3. Clean and reinstall the drain
plug.
4. Add Polaris Premium Syn-
thetic Gearcase Lubricant
(PN 2871478) to full mark on Full Operating
the fill plug/dipstick. Range
5. Check for leaks.

CAUTION: Be careful not to allow any dirt or foreign materials to enter the trans-
mission case.
67

MAINTENANCE
Front Gearcase Lubrication
Fill plug/Dipstick
Front Gearcase Lubrication

The front gearcase fill plug is located on the right side of the front gearcase.
The front gearcase lubricant level should be checked every six months or 1000
miles (1600 km), whichever comes first. Front gearcase oil should be changed
annually. With the RANGER on a level surface, remove fill plug and check the lubri-
cant level. Lubricant should be kept at the bottom thread of the fill plug hole. The
correct gearcase lubricant to use is GL5 80-90 Weight Gear Lube.
Gearcase Oil Changing Procedure

1. Remove fender panel.
2. Remove fill plug/dipstick.
3. Remove gearcase drain plug located on the bottom right hand side and drain
the oil. Catch and discard used oil properly.
4. Clean and reinstall the drain plug.
5. Add GL5 80-90 Weight Gear Lube to the bottom thread of the fill plug hole.
6. Check for leaks.
68

MAINTENANCE
The following items should be checked occasionally for tightness; or if they have
been loosened for maintenance service.
Axle and Wheel Nut Torque Specifications
Front Spindle Nut(s) Dealer Performed Service
Front Wheel Nuts 15 Ft. Lbs.
Center and Rear Hub 120 Ft. Lbs.
Retaining Nut(s)
Rear Wheel Nuts 15 Ft. Lbs.
Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component op-
erations. Service work must be performed by your authorized Polaris dealer.
69

MAINTENANCE
Rear Spring Adjustment
The rear shock absorber springs are
adjusted by rotating the adjuster in Rear Spring
the direction required to increase or Adjustment
decrease spring tension. Cam
Air Filter Service
It is recommended that the air filter be
replaced yearly. When riding in ex-
tremely dusty conditions replace-
ment will be required more often.
1. Open the hood.
2. Remove the cover. Inspect the
gasket. It should adhere tightly to
the cover and seal all the way
around.
3. Remove the air filter. Do not attempt to clean the main element.
4. Install new air filter. NOTE: Apply a small amount of general purpose grease
to the sealing edges of the filter before installing.
5. Check air box. If oil or water deposits are found, drain them into a suitable con-
tainer. NOTE: Service more frequently if vehicle is operated in wet conditions
or at high throttle openings for extended periods.
Air Filter
70

MAINTENANCE
CAUTION: Operation of your vehicle without a breather filter can cause engine
damage.
Breather Filter and Hoses

WARNING Do not perform this operation immediately after the engine
has been run. The exhaust system becomes very hot and
can cause severe burns.
1. Open hood and locate the 1
airbox (1).
2. Follow right hand breather
line out of the back of the
airbox and locate filter (2).
3. Inspect filter for debris. Blow
through gently in direction of
arrow on filter to check for
clogging. Replace as
needed.
4. Check hoses for cracks,
deterioration, abrasion, or
leaks. Replace as needed.
5. Reinstall filter and clamps 2
with arrow pointing toward
engine.
Radiator and Cooling Fan
Check and clean the grille, screen and radiator fins for obstruction by insects or
mud in accordance with the Periodic Maintenance Chart.
CAUTION: Using high-pressure water, as from a car wash facility, could damage
the radiator fins and impair the radiator’s effectiveness.
Do not obstruct or deflect airflow through the radiator by installing unauthorized ac-
cessories in front of the radiator or behind the cooling fan. Interference with the
radiator airflow can lead to overheating and consequent engine damage.
Coolant absorbs excessive heat from the engine and transfers it to the air at the
radiator. If the coolant level becomes low, the engine overheats and may suffer
damage. Check the coolant level each day before operating the vehicle, and re-
plenish coolant if the level is low. Change the coolant in accordance with the Peri-
odic Maintenance Chart.
71

MAINTENANCE
Coolant Level Inspection
NOTE: Check the coolant level
when the engine is cold (room or Radiator Cap
atmospheric temperature).
1. Situate the vehicle on level
ground.
2. Check the coolant level
through the coolant level
gauge on the reserve tank lo-
cated Behind the left hand en-
gine compartment panel. The
coolant level should be be-
tween the F (Full) and L (Low)
marks.
3. If the amount of coolant is not
within the operating range, un-
screw the cap from the reserve
tank. Using a funnel, add cool-
ant through the filler opening to Coolant Bottle
the F (Full) mark. Install the
cap.
NOTE: Polaris recommends the
use of Polaris Premium 60/40 anti-
freeze/coolant or a 50/50 mixture
of high quality aluminum compat-
ible anti-freeze/coolant and dis-
tilled water. IMPORTANT: Polaris
Premium 60/40 is already pre-
mixed and ready to use. Do not di-
lute with water. IMPORTANT: Al-
ways follow the manufacturer’s
mixing recommendations for the
freeze protection required in your
area.
NOTE: In an emergency you can add water alone to the coolant reserve tank, how-
ever it must be returned to the correct mixture ratio by the addition of antifreeze con-
centrate as soon as possible.
CAUTION: If coolant must be added often, or the reserve tank completely runs dry,
it is possible there is a leak in the system. Have the cooling system inspected by
your Polaris RANGER dealer.
72

MAINTENANCE
Spark Plugs
Proper electrode gap is .028″/.7mm.
Spark plug torque is 17 ft. lbs. (2.3 kg/m).
Use NGK BKR5ES spark plugs.
Proper electrode gap is .025″ (.06 cm).
Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs
(1.52 kg/m) for a new spark plug.
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.
1. Normal
The 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 carburetion adjustments.
2. Wet Fouled
The 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 are excessive oil, use of non-recommended injection oil, improper use of
the choke, or incorrect carburetion adjustments.
Spark Plug Removal and Replacement
WARNING: Never attempt to remove a spark plug while the engine is warm.
The exhaust system or engine could burn you causing severe injury.
The spark plug is removed by using the special wrench provided in the tool pouch
under the seat. Reach inside the right hand engine access panel and then back
for access. Remove the spark plug cap and then the spark plug by rotating coun-
terclockwise.
Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. (2.3 kg/m).
Never deviate from the recommended spark plug as engine damage can occur.
Cylinder Head/Cylinder Base Fastener Torque
Have your dealer check the RANGER cylinder head and cylinder base fasteners
for proper torque at the first service or after 25 hours.
73

MAINTENANCE
Spark Arrestor
The exhaust pipe must be period-

ically purged of accumulated car-
bon as follows:
1. Remove the clean out plugs
located on the bottom of the
muffler as shown above.
2. Place the transmission in
neutral and start the engine. Clean Out Plug
Purge accumulated carbon
from the system by momen-
tarily revving the engine sev-
eral times.
3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around
the clean out plugs while revving the engine several more times.
4. If particles are still suspected to be in the muffler, back the machine onto an in-
cline so the rear of the machine is one foot higher than the front. Set the parking
brake and block the wheels. Make sure the machine is in neutral and repeat
steps 2 and 3. WARNING: SEE BELOW.
5. If particles are still suspected to be in the muffler, drive the machine onto the
incline so the front of the machine is one foot higher than the rear. Set the park-
ing brake and block the wheels. Make sure the machine is in neutral and repeat
steps 2 and 3. WARNING: SEE BELOW.
6. Repeat steps 2 through 5 until no more particles are expelled when the engine
is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the arrestor plugs.
WARNING
Because exhaust system temperatures can reach 1000°F, do not perform
this operation immediately after the engine has been run because the ex-
haust system becomes very hot.
Because of the increased fire hazard, make sure that there are no com-
bustible materials in the area when purging the spark arrestor.
Wear eye protection.
Do not stand behind or in front of the vehicle while purging the carbon from
the spark arrestor.
Never run the engine in an enclosed area. The exhaust contains poison-
ous carbon monoxide gas.
Do not go under the machine while it is inclined.
Failure to heed these warnings could result in serious personal injury or death.
74

MAINTENANCE
Tool Kit
To help you perform routine maintenance, a tool kit is provided in the storage
compartment under the seat. Items included in the kit are:
screwdriver
open end wrench (8-10 mm)
open end wrench (12-14 mm)
tire pressure gauge
spark plug wrench and handle
NOTE: Other tools are also necessary to perform maintenance work. They are
called out later in this manual.
PVT System
WARNING
The PVT system rotates at high speeds, creating large amounts of force
on clutch components. Extensive engineering and testing has been con-
ducted to insure the safety of this product. However, as the owner you
have the following responsibilities to make sure this system remains safe:
Do not modify any component of the PVT system. Doing so may reduce
its strength so that a failure may occur at high speeds. This system has
been precision balanced. Any modification will cause the system to be
out of balance, creating vibration and additional loads on components.
Routine maintenance is the responsibility of the owner. Always follow
recommended maintenance procedures. See your dealer!
This PVT system is intended for use on Polaris products only.
The PVT housing must be securely in place during operation.
Failure to comply with this warning can result in severe injury or death.
75

MAINTENANCE
Throttle Pedal
If the throttle pedal (1) has exces-
sive play due to cable stretch or
cable misadjustment, it will cause a
delay in throttle response, especial-
ly at low engine speed. Also, the
throttle may not open fully. If the
throttle pedal has no play, the 1
throttle may be hard to control, and
the idle speed may be erratic.
Check the throttle pedal play period-
ically in accordance with the Period-
ic Maintenance Chart and adjust the
play if necessary.
Throttle Freeplay Inspection
1. Apply the parking brake.
2. Put the gear shift lever in the N
(Neutral) position.
3. Start the engine, and warm it up
thoroughly.
4. Measure the distance the
throttle pedal moves before the
engine begins to pick up speed.
Free play should be 1/16 - 1/8
inches.
Adjustment
If adjustment is necessary, adjust
the throttle freeplay using the follow-
ing procedure:
1. Loosen jam nut on cable where
it connects to the throttle brack-
et.
2. Adjust cable to specified free-
play.
3. Tighten jam nuts securely.
76

MAINTENANCE
Carburetor
The idle speed adjustment should be performed in accordance with the Periodic
Maintenance Chart or whenever the idle speed is changed. The following proce-
dure covers the idle speed adjustment:
Carburetor/Engine Idle RPM Adjustment
Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not
satisfactory, and all other conditions are favorable, the carburetor can be adjusted
as follows:
1. Apply the parking brake.
2. Put the gear shift lever in the N
(Neutral) position.
3. Warm up the engine by running
the vehicle approximately five
minutes.
4. Remove the right hand engine
compartment access panel and
locate the idle screw.
5. Place the transmission in gear
with the parking brake applied.
6. Adjust the carburetor idle screw Idle Screw
in or out until the desired idle
RPM is reached . Turning the
screw in (clockwise) will raise
RPM. Turning the screw out
(counterclockwise) will lower
RPM.
77

MAINTENANCE
Front and Rear Brakes
The front and brakes are hydraulic
disc type brakes activated by the
brake pedal.
The following checks are recom-
mended to keep the brake system in
good operating condition. How often 1
they need checking depends upon
the type of driving that has been done.
Inspect the level of the brake
fluid before each ride. Change
the brake fluid according to the
Periodic Maintenance Chart. The
brake fluid should also be
changed if it becomes contami-
nated with dirt or water.
To check the fluid level, the vehicle must be on level ground. Inspect the
brake fluid by looking at the remote reservoir (1) under the hood. The level
should be between the upper (MAX) and lower (MIN) level lines.
If the fluid level is lower than the lower level line, add brake fluid to the upper
(MAX) line. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
WARNING: Change the fluid in the brake system completely if the fluid level is low
but the type and brand of the fluid already in the reservoir are unknown.
WARNING: Once a bottle of brake fluid is opened, use what is necessary and dis-
card the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygro-
scopic, meaning it rapidly absorbs moisture from the air. This causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and the
possibility of serious injury.
Check brake system for fluid leaks.
Check brake for excessive travel or
spongy feel.
WARNING: If the brake pedal has a soft
“spongy” feeling” when it is applied, there
could be air in the brake lines or the brake may
be defective. Do not operate the vehicle under
these conditions. Have the brake system ser-
viced by an authorized Polaris dealer immedi-
ately.
Check friction pads for wear, damage 3/64″ (.1 cm)
and looseness.
Check security and surface condition of
the disc.
Pads should be changed when worn to
3/64″ (.1 cm), or about the thickness of a
dime.
78

MAINTENANCE
Rear Brake
The rear brake is a hydraulic disc
type brake which is activated by the
same pedal which activates the front
brake system. The rear brake sys-
tem is self adjusting and requires no
maintenance other than periodic
checks of the pads for wear.
Wear Line
Pads should be changed when
worn to 3/64″ (.1 cm) which is 3/64″ (.1 cm)
about the thickness of a dime.
Inspect the brake disc spline and pad wear surface for excessive wear.
WARNING: Due to the nature of this type of vehicle and where it is operated,
headlight and taillight lenses may become dirty. Frequent washing is necessary
to maintain lighting quality. Poor lighting while riding can result in severe injury or
death.
CAUTION: Do not service while lights are hot. Serious burns may result.
Brake Light Switch

When the brake pedal is depressed, the brake light goes on. Check the brake light
switch before each ride.
To inspect the brake light, first turn the ignition switch to the ON position.
Depress the brake pedal. The brake light should go on after about 10mm (0.4 in.)
of pedal travel.
If the light does not go on, check the bulb.
79

MAINTENANCE
Parking Brake Lever
The parking brake helps hold the
vehicle from rolling while parked.
Make sure the parking brake lever
is functioning properly before each
ride.
Inspection: 2
Pull the parking brake lever
up and to the rear.
1
After 8 to 12 clicks of lever
travel, the vehicle should not
roll while parked.
If the vehicle moves, adjust-
ment is necessary
Adjustment:
Loosen the locknut (1) (lower nut) on the lower end of the parking brake
lever cable and turn the nut next to the locknut (2) until the brake lever will
only move 8 - 12 clicks upward.
Tighten the locknut securely
NOTE: Be sure to hold the cable end with a wrench to prevent the cable from twist-
ing.
Steering Wheel
Check the steering wheel for specified free play and smooth operation in accor-
dance with the periodic maintenance Chart.
Inspection:
Park the vehicle on level ground.
Lightly turn the steering wheel left and right.
There should be 0.8 - 1.0 in (20 - 25 mm) of free play.
If there is excessive free play or strange noises, or the steering feels rough
or “catchy,” have the steering system checked by an authorized Polaris deal-
er.
80

MAINTENANCE
Wheel Removal Procedure
1. Stop the engine, place the transmission in gear and lock the parking 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 remove the wheel.
Wheel Installation
1. With the transmission in gear and the parking brake locked, 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.
2. Attach the wheel nuts and finger
tighten them.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts
according to the chart found on
page 69:
CAUTION: If wheels are improperly
installed it could affect vehicle han-
dling and tire wear.
81

MAINTENANCE
WARNING
Operating your vehicle with worn tires will increase the possibility of the
vehicle skidding easily with possible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.
Tire Inspection
CAUTION: Maintain proper tire pressure according to charts below. Improper tire
inflation may affect vehicle maneuverability.
When replacing a tire always use original equipment size and type.
CAUTION: The use of non-standard size or type tires may affect vehicle handling.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. Please refer
to your Owner’s Manual Supplement for tire specifications.
Minimum
Tread
Depth 1/8
(.3 cm)
Tire Specifications
RANGER 6x6
Front - 25 x 10.00 -12
Inflation Pressure - Min 5 - Max 12
Center - 25 x 11.00 - 10
Inflation Pressure - Min 5 - Max10
Rear - 25 x 11.00 - 10
Inflation Pressure - Min 5 - Max 10
Cargo Box Load Capacity
1000 lbs. ( 454 kg)
Gross Vehicle Weight 3020 lbs.
(1327 kg) including vehicle, driver, passenger and cargo. Vehicle weighs
1520 lbs. ( 690 kg).
82

MAINTENANCE
Seat Belts
Make certain each seat belt functions properly before each ride. Push the latch
plate into the buckle until it clicks. The latch plate must slide smoothly into the
buckle. The click sound shows it is securely latched. Push the red button in the
middle of the buckle to make sure it releases freely. Also check the belt webbing
for wear, cuts or damage. If any irregularities are found, have the seat belt system
checked or replaced by an authorized Polaris dealer
83

MAINTENANCE
Headlight Beam
The headlight beam can be adjusted up and down.
1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6
m) from a wall.
2. Measure the distance from the floor to the center of the headlight and make a
mark on the wall at the same height.
3. Start the engine and turn the headlight switch to high beam.
4. Observe headlight aim. The most intense part of the headlight beam should
be aimed 2″ (5.1 cm) below the mark placed on the wall in step 2. NOTE: Rider
weight must be included on the seat.
5. Loosen pivot bolts and adjust beam to desired position.
6. Tighten nut and bolt. Torque to 60 in. lbs.
Indicator Lamp Replacement

1. Unplug light from harness, depress lock-
ing tabs and remove from pod.
2. Install new light and reassemble pod.
Depress locking
tabs to remove.
84

MAINTENANCE
WARNING
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
Always refuel with the engine stopped and outdoors or in a well venti-
lated area.
Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
Do not over fill the tank.
If you should get gasoline 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 pow-
ered engine exhaust fumes are poisonous and can cause loss of con-
sciousness and death in a short time.
Shut off fuel valve whenever the vehicle is stored or parked.
WARNING
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.
85

MAINTENANCE
Cleaning Your RANGER
Keeping your vehicle clean will not only improve its appearance but it can also ex-
tend the life of various components. With a few precautions, your vehicle can be
cleaned much like an automobile.
Washing
If a high pressure type car wash system is used, extreme care must be taken to
avoid water damage to the wheel bearings, transmission seals, body panels,
brakes, headlights and warning labels. Many expensive repair bills can result from
using high pressure detergent systems.
NOTE: If a high pressure car wash is used, grease all zerk fittings immediately af-
ter washing. Also run the vehicle to evaporate any water that might have entered
the engine or exhaust system.
The best and safest way to clean your vehicle is with a garden hose and a pail of
mild soap and water. Use a professional type washing mitten, cleaning the upper
body first and the lower parts last. Rinse with water frequently and dry with a cham-
ois to prevent water spots. NOTE: If warning labels are damaged, contact your
a Polaris dealer for free replacement.
86

MAINTENANCE
Storage
If your vehicle is to be placed in extended
or off season storage, the following steps
should be taken to preserve its condition.
1. Perform all necessary repairs and thor-
oughly clean the vehicle.
2. Turn the fuel valve to “off” and drain the
carburetor.
Drain tube
3. Remove the spark plug and pour attached
approximately one ounce of Pre- here
mium 4 oil into the cylinder. Oper-
ate the starter for a few seconds Drain Screw
and reinstall the spark plug.
4. Remove the battery. Store it in a cool, dry place out of the sun.
5. Lubricate suspension pivot points, lower steering post and rear axle fittings.
6. Drain the recoil housing.
7. Block the vehicle so all tires are suspended off the ground.
8. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil
on rubber parts or in the brakes.
9. Lubricate all cables.
10. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture
or small animals from entering.
11. Cover the vehicle with a canvas cover. Do not use plastic or coated materials
since they do not allow ventilation of the vehicle.
Removal from Storage:

1. Check the battery electrolyte level, charge the battery if necessary, and install
it in the vehicle. Take care the battery vent hose is not pinched and routed prop-
erly.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Safety Checks section.
5. Lubricate per periodic maintenance chart.
87

MAINTENANCE
WARNING
Do not run the engine in a closed area. Exhaust gases contain carbon
monoxide; a colorless, odorless, poisonous gas. Breathing exhaust
gas leads to carbon monoxide poisoning, asphyxiation and death.
Bolt and Nut Tightening

Tightness of the bolts, nuts and other fasteners should be checked by an autho-
rized Polaris dealer in accordance with the Periodic Maintenance Chart.
88

TROUBLESHOOTING
Procedures
The following information is provided to help you identify probable causes for ques-
tions you may have about the operation of your vehicle. See your Polaris dealer
with any additional questions you may have.
ENGINE CRANKS BUT FAILS TO START
No Fuel Water in Fuel Spark Plug
Fuel Valve Off Drain System No Spark to

Spark Plug
Clogged Fuel Contact Your

Valve Dealer
ENGINE STOPS OR LOSES POWER
No Fuel Overuse of Spark Plug Engine

Choke Fouled Overheated
Fuel Vent Line

Air Filter Clean Radiator
Kinked or
Clogged screen
Plugged
Water in Fuel Contact Your Clean Engine

Dealer Exterior
Fuel Pump Contact Your

Faulty Dealer
Contact Your
Dealer
89

SPECIFICATIONS
Gross Vehicle Weight 3020 lbs.
Fuel Capacity 9.5 Gallons
Towing Capacity 1500 lbs.
C
A Maximum Cargo Box Load 1000 lbs.
P Overall Length 113 in.
A
C Overall Width 58 in. (Tires) 60″ (Cargo Box)
I Overall Height 75 in.
T
I Wheelbase 81 in.
E Ground Clearance 8.5 in.
S
Dry Weight 1520 lbs.
Cargo Box (L x W x H) 40 x 59.75 x 9
Minimum Turning Radius 168 in.
Engine Oil Capacity 2 Quarts
Coolant Capacity 2.25 Quarts
Type 4 Cycle, Single Cylinder
Displacement 498
Bore x Stroke 90 x 75
Pilot Jet 42.5
Main Jet 125
Needle Jet Q-6
Jet Needle 5D78-3
E Air Screw 1.25 Turns
N
G Alternator Output 250 W
I Compression Ratio 10.2:1 Full Stroke
N
E Starting System Electric Start w/Recoil Backup
Carburetor 1 - BST 34 (CV Type)
Ignition System CDI
Ignition Timing 30° @ 3500 ± 1.5
Spark Plug NGK BKR5E
Lubrication System Dry Sump
Engine Oil 0W/40
90

SPECIFICATIONS
Driving System Type PVT
D
Shift Type Single Lever/Center Console
R
I Gear Reduction - Low 24.16:1
V
E Gear Reduction - Reverse 18.67:1
Gear Reduction - High 11.97:1
T
R Drive Ratio - Front: 2:1
A Drive Ratio - Final 3.5:1
I
N Drive Ratio - Center 1:3.5
Front Final Gear Case Oil Capacity 32 ounces
T Tire Size - Front 25 x 10 - 12 (12 psi MAX)
I
R Tire Size - Rear 25 x 11 - 10 (10 psi MAX)
E
S Tire Size - Center 25 x 11 - 10 (10 psi MAX)
Type Foot pedal activated hydraulic front

and rear.
rear Mechanical Parking
B Brake
R
Front Hydraulic disc, Floating caliper
A
K
E Rear (Center Axle) Hydraulic Disc, floating Caliper
S
Parking
g Brake Hand Lever
Mechanical to center Axle
L Hood Headlight (watts) 4 x 35W
I
G Taillights (watts) 2 x 8.26W
H Brake Light (watts) 26.9
T
S Indicator Light (watts) 1
91

WARRANTY
92

WARRANTY
LIMITED WARRANTY
Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota
55441-5078, gives a SIX MONTH LIMITED WARRANTY on all components of the
Polaris RANGER against defects in material or workmanship. This warranty cov-
ers 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. There is a charge of $35.00 payable to Polaris Industries Inc.
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 war-
ranty entitlement. If you have not signed the original registration and received the
“customer copy”, please contact your dealer immediately. NO WARRANTY COV-
ERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH
POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring
trouble-free operation. Purchasing a machine in the crate or without proper dealer
set-up will void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect
in material or workmanship. This warranty does not cover accidental damage, nor-
mal 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 uphol-
stery material, corrosion, or defects in parts, components or the vehicle due to fire,
explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or
fuels that are not compatible with the vehicle. The exclusive remedy for breach of
this warranty shall be, at Polaris’ exclusive option, repair or replacement of any de-
fective materials, or components or products. THE REMEDIES SET FORTH IN
THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON
FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO
ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES
OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED
93

WARRANTY
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT
OR OTHERWISE. Some states do not permit the exclusion or limitation of inciden-
tal or consequential damages or implied warranties, so the above limitations or ex-
clusions may not apply to you if inconsistent with controlling state law.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WAR-
RANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRAN-
TIES 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 War-
ranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO
AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that
you use your original selling dealer; however, you may use any Polaris Servicing
Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer
require any additional assistance they will contact the appropriate person at Polar-
is.
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.
Engine Oil
1. Always use Polaris engine oil.
2. Never substitute or mix oil brands as serious engine damage and voiding of war-
ranty can result.
94

INDEX
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 70 Maintenance Schedule . . . . . . . . . . . 60-61
All Wheel Drive . . . . . . . . . . . . . . . . . . . 31 Noise Control System . . . . . . . . . . . . . 56
Backing Up . . . . . . . . . . . . . . . . . . . . . . 54 Oil Change . . . . . . . . . . . . . . . . . . . . 38-39
Battery Installation . . . . . . . . . . . . . . . . 58 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . 39
Battery Maintenance . . . . . . . . . . . . . . 57 Oil System . . . . . . . . . . . . . . . . . 24 and 37
Battery Removal . . . . . . . . . . . . . . . . . . 58 Operating Safety . . . . . . . . . . . . . . . . 46-55
Brake, Front . . . . . . . . . . . . . . . . . . . . . 78 Operation Warnings . . . . . . . . . . . . . 10-19
Brake, Rear . . . . . . . . . . . . . . . . . . . . . . 79 Parking On An Incline . . . . . . . . . . . . . 54
Break In Period . . . . . . . . . . . . . . . . . . . 44 Premium 4 Synthetic Lubricant . . . . . . 37
Carburetor Adjustment . . . . . . . . . . . . . 77 PVT System . . . . . . . . . . . . . . . 33 and 75
Carrying Loads . . . . . . . . . . . . . . . . . . . 45 Rear Spring Adjustment . . . . . . . . . . . . 70
Cleaning Your RANGER . . . . . . . . . . . 86 Recoil Starter . . . . . . . . . . . . . . . . . . . . 43
Control And Parts Functions . . . . . . 31-43 Riding On Slippery Surfaces . . . . . . . . 48
Control Parts And Functions . . . . . . 27-30 Spark Arrestor . . . . . . . . . . . . . . . . . . . . 74
Coolant Level . . . . . . . . . . . . . . . . . . . . 34 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . 73
Coolant Level Inspection . . . . . . . . . . . 35 Starting A Cold Engine . . . . . . . . . . . . . 40
Crossing Streams . . . . . . . . . . . . . . . . . 52 Starting A Warm Engine . . . . . . . . . . . . 42
Cylinder Head Torque . . . . . . . . . . . . . . 73 Starting The Engine . . . . . . . . . . . . . 40-42
Daily Pre-ride Inspection . . . . . . . . . . . . 9 Tire Inspection . . . . . . . . . . . . . . . . . . . . 82
Demand 6 Drive . . . . . . . . . . . . . . . . . . 31 Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Disengaging Wheel Hubs . . . . . . . . . . 33 Torque Specifications . . . . . . . . . . . . . . 69
Dumping Cargo Bed . . . . . . . . . . . . . 45-55 Towing Capacities . . . . . . . . . . . . . . . . . 45
Engine Cooling System . . . . . . . . . . 34-36 Trail Obstacles . . . . . . . . . . . . . . . . . . . 53
Engine Idle Rpm Adjustment . . . . . . . . 77 Transmission Gear Selector
Filter Change . . . . . . . . . . . . . . . . . . . 38-39 Operation . . . . . . . . . . . . . . . . . . . 32
Front Gearcase Lubrication . . . . . . . . . 68 Transmission Oil Changing
Front Wheel Hub Tightening . . . . . . . . 69 Procedure . . . . . . . . . . . . . . . . . . . 67
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . 39 Troubleshooting . . . . . . . . . . . . . . . . . . 89
Fuel System . . . . . . . . . . . . . . . . . . . . . 24 Understanding Warnings . . . . . . . . . . . . 1
Gearcase Oil Changing Procedure . . . 68 Vehicle Identification Numbers . . . . . . 20
Indicator Lamp Replacement . . . . . . . . 84 Warranty . . . . . . . . . . . . . . . . . . . . . . 92-93
Load Distribution . . . . . . . . . . . . . . . . 46-47 Wheel Installation . . . . . . . . . . . . . . . . . 81
Lubrication Recommendations . . . . 62-65 Wheel Removal . . . . . . . . . . . . . . . . . . . 81
Maintenance . . . . . . . . . . . . . . . . . . . 59-88
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PROTECT YOUR SPORT

Know all local, state/province off-road vehicle laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as

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FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.

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Additional Important Information...

Familiarize yourself with their function and affect on the vehicle.

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As a PRO Family member, you’re entitled to opportunities such as:

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Indicates a potential hazard

Indicates a potential hazard which

The word “NOTE:” in this manual will alert

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

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l Riders can be thrown off.

IMPROPER TIRE PRESSURE OR OVER-

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HEADLAMPS ARE NOT SEALED.

Recoil handle must be firmly seated to

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Text found below

OPERATOR/LOAD DISTRIBUTION WARNINGS

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Text found below

READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFORE

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2. Vehicle Model Number:

3. Engine Serial Number (Right front side of engine crankcase)

Ignition Key Number

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ON All electrical equipment can be used.

START Electric starter is engaged by holding ignition switch key in

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WARNING: Once a bottle of brake

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Oil Filter 100 hrs/1000 6 months Replace with oil change

Engine breather filter 20 hrs Monthly Inspect–replace annually and as need-

Engine breather hose 100 hrs 6 months Inspect

Air Filter - Main Element Weekly Weekly Inspect-Replace if necessary

Valve Clearance 100 hrs 12 months Inspect/Adjust

Spark Plug 100 hrs 12 months Inspect–replace if necessary

Ignition Timing 100 hrs 12 months Inspect and adjust as needed

Fuel Filter 100 hrs 12 months Replace annually

Idle Speed As Required As Required Adjust

Throttle Cable 50 hrs 6 months Inspect–adjust, lubricate, replace if nec-

Choke (Enricher) Cable 50 hrs 6 months Inspect–adjust, lubricate, replace if nec-