Polaris Ranger 1000, 1000 Crew v3 Owner's Manual PDF

Pages 176
Year 2020
Language(s)
English en
1 of 176
1 of 176

Summary of Content for Polaris Ranger 1000, 1000 Crew v3 Owner's Manual PDF

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POLARIS, RANGER, and POLARIS GENERAL are trademarks of POLARIS Industries Inc... Copyright 2019 Polaris Industries Inc... All information contained within this publication is based on the latest product information at the time of publication... Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited... The original instructions for this vehicle are in English... Other languages are provided as translations of the original instructions... Printed in U... S... A... 9930790

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For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Review the safety DVD that came with your vehicle... POLARIS also recommends that all drivers take the ROHVA safety e-course and a ROHVA hands-on safety training course... Visit www... rohva... org or call 866-267-2751...

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The following signal words and symbols appear throughout this manual and on your vehicle... Your safety is involved when these words and symbols are used... Become familiar with their meanings before reading the manual...

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Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 97 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 145 POLARIS Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 151 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 153 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 157 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 167

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WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death... Your POLARIS vehicle is not a toy and can be hazardous to operate... This vehicle handles differently than cars, trucks or other off-road vehicles... A collision or rollover can occur quickly, even during

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Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature

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VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided... Remove the spare key and store it in a safe place... An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys... The ignition switch must be replaced if all keys are lost...

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SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS... POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course... ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course... Visit www... rohva... org or call 866- 267-2751...

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RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area... The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time... The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow... Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow...

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HELMET Wearing a helmet can prevent a severe head injury... Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards... Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head... Parents should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation...

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CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle... When vehicle is stopped, place shift in parked position...

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RANGER 1000 SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection... Read and follow the instructions of the labels on the vehicle carefully... If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle... If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement... Replacement safety labels are provided by POLARIS at no charge... The part number is printed on the label...

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Fasten seat belts... Wear an approved helmet and protective gear... ALWAYS use vehicle cab doors if equipped... Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or handholds... Stay completely inside the vehicle...

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AIR BOX CAUTION CAUTION Use a Polaris approved air filter... The use of a non-Polaris approved air filter may cause engine damage... Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube... The air filter must be properly seated before the lid is reinstalled... Please reference your owners manual for additional information regarding air filter service...

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FUEL TRANSPORT WARNING The Fuel Transport Warningq is located in the cargo box... WARNING NEVER carry fuel or other flammable liquids on this vehicle... Failure to follow this instruction could lead to serious burn injuries or death...

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RANGER CREW 1000 SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection... Read and follow the instructions of the labels on the vehicle carefully... If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle... If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement... Replacement safety labels are provided by POLARIS at no charge... The part number is printed on the label...

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Fasten seat belts... Wear an approved helmet and protective gear... ALWAYS use vehicle cab doors if equipped... Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or handholds... Stay completely inside the vehicle...

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Reduce speed and allow greater distance for braking when carrying cargo... Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control... Loads should be centered and carried as low as possible in box...

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AIR BOX CAUTION CAUTION Use a Polaris approved air filter... The use of a non-Polaris approved air filter may cause engine damage... Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube... The air filter must be properly seated before the lid is reinstalled... Please reference your owners manual for additional information regarding air filter service...

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Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death... Heed all safety warnings outlined in this section of the owners manual and in the safety DVD

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Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills... Check the terrain carefully before descending a hill... Never travel downhill at high speed... Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side... Travel straight down the hill where possible...

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AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY... Operation is prohibited for anyone under 16 years of age or anyone without a valid drivers license... The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel (if equipped) or handlebars...

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PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident... Operator and/or all passengers must always wear an approved helmet that fits properly, gloves, long-sleeve shirt, long pants, over-the-ankle boots, and eye protection (goggles or face shield)...

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CARRYING A PASSENGER A passenger must always be seated in a passenger seat with seat belt secured... Carrying more than one passenger in a 2-seat vehicle can affect the operators ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover... Never carry more than one passenger in a 2-seat vehicle unless specified otherwise...

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OPERATING ON PAVEMENT This vehicle's tires are designed for off-road use only, not for use on pavement... Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover... Avoid operating the vehicle on pavement... If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops...

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Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle... Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-

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Never apply engine power... Apply the brakes gradually until the vehicle is fully stopped... Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed...

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Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover... Do not operate on excessively slippery surfaces... Always slow down and use

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Severe injury or death can result if the vehicle and/or the operator fall through the ice... Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in

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Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street... This vehicle is not equipped with highway-approved lights... Operate this vehicle off-road only... Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness... Clean headlights frequently and replace

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EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed... Modifications to your vehicle may negatively impact vehicle stability... Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power... This vehicle may become less stable at speeds higher than those for which it is designed... Loss of control may occur at higher speeds... Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power... Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury...

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i Receiver Hitch o ROPS Cab Frame a Hip Bar s Cargo Box d Fuel Cap f Fuse Block (underneath seat)

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q Console w Headlights e Radiator r Bumper/Brush Guard t Tailgate y Taillights u CV Boot/Rear Caliper

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STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference... Lift and hold the steering wheel adjustment leverq while moving the steering wheel upward or downward... Release the lever when the steering wheel is at the desired position... Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls...

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Low gear is the primary driving range for the RANGER... High gear is intended for use on hard-packed surfaces with light loads... Whenever the vehicle is left unattended, always place the transmission in PARK...

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USING LOW GEAR Low gear is the primary driving range for the RANGER... High gear is intended for use on hard-packed surfaces with light loads... Whenever the vehicle is left unattended, always place the transmission in PARK... Always shift into low gear for any of the following conditions...

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LIGHT SWITCH The ignition switch key must be in the ON/ RUN position to operate the headlights... Press the top of the rocker switch toward the dash to place the headlights on high beam... Move the rocker switch to the center position to place the headlights on low beam... Press the bottom of the rocker switch to turn off the headlights...

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AWD SWITCH The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode)... Press the top of the switch to engage All Wheel Drive (AWD)... Move the switch to the center position to lock the differential and operate in two wheel drive (2WD)... Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD)... This mode of operation is well suited to turf driving or when active traction is not needed...

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THROTTLE PEDAL Push the throttle pedalw down to increase engine speed... Spring pressure returns the pedal to the rest position when released... Always check that the throttle pedal returns normally before starting the engine...

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PARK BRAKE LEVER (IF EQUIPPED) Always apply the service brakes before engaging or releasing the park brake... To help prevent the vehicle from rolling, set the park brake when parking the vehicle... When the park brake is set and the park brake indicator is illuminated, engine speed is limited... If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear...

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This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger... Always make sure the seat belts are secured for all riders before operating... The drivers seat belt is equipped with a seat belt interlock... Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured... The center of the seat is NOTequipped with a seat belt... Never allow a passenger to ride between the operator and passenger seats...

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SEAT AND STORAGE COMPARTMENTS The electrical compartment is located under the center rear-most seat... Never use this area for storage... Storage compartments are located under all other seats... Remove the storage bin under the right rear-most passenger seat to access the battery... If your model is equipped with a storage console and cup holders located between the front seats, lift the console lid to access the storage compartment...

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This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers... Always make sure the seat belts are secured for all riders before operating... The drivers seat belt is equipped with a seat belt interlock... Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured...

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SEAT AND STORAGE COMPARTMENTS The electrical compartment is located under the center rear-most seat... Never use this area for storage... Storage compartments are located under all other seats... Remove the storage bin under the right rear-most passenger seat to access the battery... Always make sure all seats are properly installed before operating... Push down firmly on the rear of each seat until the latch pins are fully seated into the grommets...

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ELECTRONIC POWER STEERING (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position... EPS remains engaged whether the vehicle is moving or idle... To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position... The EPS warning indicator will illuminate to indicate the EPS has shut down... Turn the key off and on to reset the unit... If the light remains on after starting the engine, the EPS system is inoperative... See your POLARIS dealer, or other qualified person, as soon as possible for repair... Continued operation could result in permanent damage to the EPS unit and increased steering effort...

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ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928... 53 rollover performance requirements... Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way... No device can assure occupant protection in the event of a rollover... Always follow all safe operating practices outlined in this manual to avoid vehicle rollover...

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NOTICE The use of a high pressure washer may damage the instrument cluster... Wash the vehicle by hand or with a garden hose using mild soap... Do not use alcohol to clean the instrument cluster... Do not allow insect sprays to contact the lens... Immediately clean off any gasoline that splashes on the instrument cluster...

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q Check Engine This indicator appears if an EFI-related fault occurs... Do not operate the vehicle if this warning appears... Serious engine damage could result... Your authorized POLARIS dealer can assist...

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Pressing the MODE button will change the information displayed in Area 1q...

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Toggle the Up/Down buttons to change the information displayed in Area 2w...

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Diagnostic Codes Only displays if fault codes are present or stored

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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oWith the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu...

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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3... To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu...

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DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc... ), or the item has failed... Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart...

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Starter Enable Circuit Driver Circuit Open/ Grounded 1321 5

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Chassis Relay Driver Circuit Open/ Grounded 520208 5

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Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level

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Data Valid But Above Normal Operating Range - Moderately Severe Level

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VEHICLE BREAK-IN PERIOD The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 full tanks of gasoline... No single action on your part is as important as a proper break-in period... Careful treatment of a new engine will result in more efficient performance and longer life for the engine... Perform the following procedures carefully...

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KNOW YOUR RIDING AREA/TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area... Respect the environment in which you ride your vehicle... Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials... Help keep our trails open for recreational vehicle use... As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow... Tread lightly... Operate with respect for the terrain, avoid littering, and always stay on the designated trails...

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7... Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience... Never operate at excessive speeds... Never attempt wheelies, jumps, or other stunts... Keep both hands on the steering wheel during operation...

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Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident... Always inspect the vehicle

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Grass and leaves Remove grass, leaves, and other flammable material or debris, especially near the exhaust system...

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COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently... A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase... Water in the bottom of the crankcase can lead to engine damage and must be drained... Water accumulation increases as outside temperature decreases...

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structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights...

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loads in rough terrain, while cornering, or while ascending or descending a hill... Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components... Never allow a passenger to ride in the cargo

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Your vehicle has been designed to carry or tow specific capacities... Reduce speed and allow a greater distance for braking when carrying cargo... Loads should be centered on the vehicle and carried as low as possible in the box... For stability on rough or hilly terrain, reduce both speed and cargo... Exercise caution if the cargo load extends over the side of the box...

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5... Attach a trailer to the trailer hitch bracket only... Do not attach a trailer to any other location, which could result in loss of control of the vehicle...

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WARNING Operating the vehicle while the cargo box is raised could result in severe injury... The box could close unexpectedly and cause injury to the driver or passenger... The rear tires will also catch the rear of a raised box, damaging the vehicle and

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Press the top of the switch to engage All Wheel Drive (AWD)... The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD... When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction... When the rear wheels regain traction, the front gearcase will automatically disengage... There is no limit to the length of time the vehicle may remain in AWD... Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100... Once enabled, the AWD remains enabled until the AWD switch is turned off... If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction...

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LOCKING THE DIFFERENTIAL Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD)... Locking the differential in slippery or low traction conditions helps improve traction... When the rear differential is locked, both rear wheels rotate at the same speed...

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UNLOCKING THE DIFFERENTIAL (TURF MODE) When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns... Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage... DO NOToperate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings... Always operate in AWD on these types of terrain...

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16... After you become skilled at making turns and begin to operate at faster speeds, follow these precautions: Avoid sharp turns... Never turn while applying heavy throttle... Never make abrupt steering maneuvers... Operate at speeds appropriate for your skills, the conditions and the terrain...

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7... Slow down... Always travel at a speed appropriate for your skills, your passengers skills, and operating conditions... Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger...

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When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding... Follow these precautions when encountering slippery conditions:

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DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended... Improper procedure could cause loss of control or rollover... Avoid crossing the side of any hill unless absolutely necessary... If crossing a sidehill is unavoidable, follow these precautions:

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WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast- flowing water, which could result in loss of control and lead to serious injury or

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2... When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights...

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9... Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times... The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load...

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15... The winch motor may become hot during winch use... If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again...

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Take your time to think through the winching you are about to do... Proceed slowly and deliberately... Never hurry or rush during winching... Always pay attention to your surroundings... You may need to change your winching strategy if it is not working... Always remember that your winch is very powerful... There are simply some situations that you and your winch will not be able to deal with... Do not be afraid to ask others to help when this happens...

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WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks... This can result in SEVERE INJURY

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a... In order to absorb energy that could be released by a winch cable failure, always place a damper on the winch cable... A damper can be heavy jacket, tarp, or other soft, dense object... A damper can absorb much of the energy released if a winch cable breaks when winching... Even a tree limb can help as a damper if no other items are available to you...

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11... The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck... The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle... See the Shock Loading section on page 95... For your safety, always follow these guidelines when winching a vehicle free:

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14... The winch motor may become hot during winch use... If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again...

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A winch cable made of synthetic rope should be inspected for signs of fraying... Replace the cable if fraying is observed (shown below)... Promptly discontinue use of a winch cable in this condition... Also replace the winch cable if there are fused or melted fibers... Such an area of the synthetic rope will be stiff and appear smooth or glazed... Promptly discontinue use of a winch cable in this condition...

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1... Never attempt to jerk a load with the winch... For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object... This is a dangerous practice... It generates high winch cable loads that may exceed the strength of the cable... Even a slowly moving vehicle can create large shock loads in a winch cable...

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6... Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store... Although they may look similar, they are NOTalike... A polymer rope not designed for winch use will stretch and store excessive energy when winching...

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OPERATION ON PUBLIC LANDS IN THE U... S... A... Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C... Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands... Operation of off-road vehicles on public lands in the U... S... A... is regulated by 43 CFR 420... Violations are subject to monetary penalties... Federal regulations can be viewed online at www... gpoaccess... gov/ecfr/...

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MAINTENANCE PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle... An authorized POLARIS dealer can perform any service that may be necessary for your vehicle... POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used... It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicles emission controls... Tampering with emission controls is prohibited by federal law...

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PERIODIC MAINTENANCE CHART Perform all services at whichever maintenance interval is reached first... Record maintenance and service in the Maintenance Log...

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Check for leaks at tank cap, lines, filter, pump, throttle body, replace if necessary

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Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc...

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LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions... Items not listed in the chart should be lubricated at the general lubrication interval... ITEM LUBE METHOD

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ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart... Always use the recommended engine oil... Always change the oil filter whenever changing oil... Pay special attention to the oil level... A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase... Change oil immediately if the oil level begins to rise... Monitor the oil level, and if it continues to rise, discontinue use and determine the cause... Your dealer can assist...

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NOTE A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase... If the oil

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ENGINE OIL AND FILTER REPLACEMENT Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart... Always change the oil filter whenever changing the engine oil... The engine oil dipstick is located on the right front side of the engine... The engine oil fill cap is located on top of the valve cover... Access the oil dipstick and oil fill cap by tilting the rear cargo box...

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9... Lubricate the O-ring on the new oil filter with a film of fresh engine oil... Check to make sure the O-ring is in good condition... Install it to specification...

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TRANSMISSION (MAIN GEARCASE) TRANSMISSION OIL CHECK Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart... Maintain the oil level even with the bottom thread of the fill plug hole... The fill plug is located on the rear of the gearcase... Maintain the fluid level at the bottom of the fill plug hole...

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DEMAND DRIVE (FRONT GEARCASE) DEMAND DRIVE OIL CHECK Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart... Maintain the oil level even with the bottom thread of the fill plug hole... Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications... The front gearcase fill plugq is located on the right side of the front gearcase...

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7... Add the recommended fluid to the bottom of the fill plug hole... Do not overfill...

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NORMAL PLUG The normal insulator tip is gray, tan or light brown... There will be few combustion deposits... The electrodes are not burned or eroded... This indicates the proper type and heat range for the engine and the service... The tip should not be white... A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments...

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COOLING SYSTEM The engine coolant level is controlled or maintained by the recovery system... The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose... As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle... As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator...

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RADIATOR COOLANT LEVEL Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart... Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan... Interference with the radiator air flow can lead to overheating and consequentially, engine damage...

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OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart... Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool)...

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system has been precision balanced... Any modification will cause the system to be out of balance, creating vibration and additional loads on components... The PVTsystem rotates at high speeds, creating large amounts of force on clutch components... As the owner, you have the following responsibilities for

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BELT REMOVAL If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt...

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1... Inspect belt for hour-glassing (extreme circular wear in at least one spot and on both sides of the belt)... Hour glassing occurs when the drive train does not move and the drive clutch engages the belt...

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4... Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch...

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POLARIS VARIABLE TRANSMISSION (PVT) DRYING There may be some instances when water is ingested into the PVTsystem... Use the following instructions to dry it out before operating:

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6... Take the vehicle in for service as soon as possible, whether you succeed in starting it or not... Your POLARIS dealer can provide the required service...

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FILTER SYSTEMS AIR FILTER REPLACEMENT Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart... In extremely dusty conditions, air filter replacement will be required more often...

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5... Place the air filter into the airbox... Reposition the lower airbox cover and install the three retaining latches...

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Do NOT perform service on the spark arrester while the system is HOT... Exhaust system temperatures can reach extreme temperatures... Allow components to cool sufficiently before proceeding...

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store or use a partial bottle... Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air... The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of

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Do not apply WD-40 or any petroleum product to brake discs... These types of products are flammable and may also reduce the friction between the brake

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Always return the suspension to the lowest (softest) setting after the load is removed from the vehicle... The increased suspension height will negatively impact vehicle stability when operating without a load...

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REAR CAM ADJUSTMENTS The rear suspension cams can be adjusted to provide a stiffer suspension, if necessary... Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension...

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Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death... Always replace tires when the tread depth measures 3 mm (1/8) or less... Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury... Always maintain proper tire pressure... Always use POLARIS

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handling, which can result in serious injury or death... Always ensure that all nuts are torqued to specification... Do not service axle nuts that have a cotter pin

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LIGHTS Poor lighting can result in reduced visibility when driving... Headlight and taillight lenses become dirty during normal operation... Clean lights frequently and replace burned out lamps promptly... Do not operate this vehicle at night or in low light conditions until the headlight is replaced... Always make sure lights are adjusted properly for best visibility... When servicing a halogen lamp, don't touch the lamp with bare fingers... Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp...

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4... The most intense part of the LOW beam headlight beam should be aimed 7... 5 in (19... 0 cm)q below the mark placed on the wall...

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BRAKE LIGHTS When the brake pedal is depressed, the brake light comes on... Check the brake light before each ride... To check the brake lights, do the following:

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FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement... Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse... The fuse box is located under the hood... Spare fuses are provided in the fuse box... If you suspect that a fuse or relay may not be working properly, your dealer can assist...

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Your vehicle has a low-maintenance flooded battery... It does not require refilling... Always keep battery terminals and connections free of corrosion... If cleaning is necessary, remove the corrosion with a stiff wire brush... Wash with a solution of one tablespoon baking soda and one cup water... Rinse well with tap water and dry off with clean shop towels... Coat the terminals with dielectric grease or petroleum jelly... Be careful not to allow cleaning solution or tap water into a conventional battery...

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If you do not drive the vehicle for more than TWOWEEKS, Polaris recommends using a BatteryMINDer 1510 1... 5 AMP (PN 2830404) or 12V 1... 5 AMP Convertible BatteryMINDer (PN 2830511), which can be ordered through your dealer... During charging, place the charger outside of the vehicle and protect it from moisture...

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BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place... Check battery voltage each month during storage and recharge as needed to maintain a full charge...

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WASHING TIPS Avoid the use of harsh cleaners, which can scratch the finish... Do not use a power washer to clean the vehicle... Do not use medium to heavy duty compounds on the finish... Always use clean cloths and pads for cleaning and polishing... Old or reused cloths and pads may contain dirt particles that will scratch the finish...

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CHROME WHEEL CARE (IF EQUIPPED) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a like new appearance for many years... Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned... Clean chrome wheels more often if they're exposed to salt or other corrosive elements...

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2... Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers... Follow the instructions on the container for the recommended amount... Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems...

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2... Remove the spark plugs and add 2-3 tablespoons of engine oil... To access the plug holes, use a section of clear 6 mm (1/4) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil... Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak...

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1... Check the battery electrolyte level and charge the battery if necessary... Install it in the vehicle... Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way...

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Failure to comply may allow airflow, vibration, or other factors to separate the roof from the vehicle and cause an accident, resulting in serious personal

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FRONT TIE-DOWN LOCATION q Front tie-down points, one or both

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REAR TIE-DOWN LOCATION w Rear tie-down points

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SPECIFICATIONS RANGER 1000 Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories)

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Tire Size - Front Base Model: 25 x 10-12 NHS; 489 LE: 26 x 9-12; PXT 2... 0

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Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

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RANGER CREW 1000 Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories)

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Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

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Hood Headlights 2 single beam, 50W, quartz/halogen

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POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS

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Warm the engine at least 5 minutes... With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times... The belt will become more flexible and prevent belt burning...

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Fouled or defective spark plug Inspect plug and replace if necessary

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Clogged intake pre-filter Inspect and clean (with soapy water) or replace

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Overheated engine Clean radiator screen and core, clean engine exterior... Your dealer can assist...

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WARRANTY LIMITED WARRANTY POLARIS Industries Inc... , 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a ONE YEAR LIMITED WARRANTYon all components of your POLARIS vehicle against defects in material or workmanship... POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations... This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser... This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty... The duration of this warranty may vary by international region based upon local laws and regulations...

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WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship... THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN... This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling... This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed... This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center...

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This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time... THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OFANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTYARE 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 OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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IF YOU MOVE: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move... Product importation rules vary considerably from country to country... You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage... You may also be required to obtain documentation from POLARIS in order to register your product in your new country... You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle...

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EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION... This policy does not apply to products that have received authorization for export from POLARIS... Dealers may not give authorization for export... You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions... This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location... This policy does not apply to Safety Bulletins...

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U... S... A... EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle... POLARIS Industries Inc... warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U... S... Environmental Protection Agency emission regulations... POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations... The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole... The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension...

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Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance... The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products... THE REMEDIES SET FORTH IN THIS LIMITED WARRANTYARE 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 OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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CALIFORNIA RESIDENTS Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions... Only the 50-state models are certified for sale in California... The 50- state models available for sale in California are identified by the letter B in the ninth position of the model number (e... g... , R16RTE87B)... The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity... Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer... The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreational Vehicle in California if the vehicle is equipped with an evaporative emission control system and is labeled with a Vehicle Evaporative Emissions Control Information label indicating that the vehicle conforms to California evaporative emissions regulations applicable to new off-road sport vehicles, all-terrain vehicles, or off-road utility vehicles... These vehicles are referred to as OHRV-EVAP below...

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OWNER'S WARRANTY RESPONSIBILITIES: As the OHRV-EVAP owner, you are responsible for the performance of the required maintenance listed in your owner's manual... Polaris recommends that you retain all receipts covering maintenance on your OHRV-EVAP, but Polaris cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of a scheduled maintenance... As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists... The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days... As an OHRV-EVAP owner, you should also be aware that Polaris may deny you warranty coverage if your OHRV-EVAP or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications...

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MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance...

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E Electromagnetic Interference ... 97 Electronic Power Steering ... 48 Emissions Limited Warranty... 162 Engine and Drivetrain Break-in ... 67 Engine Backfires ... 154 Engine Doesn't Turn Over ... 154 Engine Oil ... 104 Engine Oil and Filter Replacement ... 106 Engine Pings or Knocks ... 155 Engine Runs Irregularly, Stalls or Misfires ... 155 Engine Stopping... 72 Engine Stops or Loses Power ... 156 Engine Turns Over, Fails to Start ... 154 European Vibration and Noise ... 8 Exhaust Emission Control System ... 97

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Instrument Cluster Back Light Color ... 58 Back Light Level ... 59 Clock ... 57 Diagnostic Code... 61 Display Area 1 ... 52 Display Area 2 ... 53 Indicator Lamps ... 51 Options Menu ... 54 Overview ... 50 Service Hours ... 60 Unit Selection Distance... 55 Unit Selection Temperature... 56

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S Safe Operation Practices ... 68 Safe Riding Gear... 11 Safety Labels and Locations ... 15, 19 Safety Symbols ... 4 Safety Training... 11 Safety Warnings... 23 Safety, Winch Maintenance... 96 Seat and Storage Compartments ... 45, 47 Seat Belt... 44, 46 Seat Belt / Drive Responsibly Warning ... 16, 20 Seat Belts ... 26 Seat Removal ... 44, 46 Shock Loading the Winch ... 95 Signal Words ... 4 Spark Arrester ... 123 Spark Plug Gap/Torque... 111 Spark Plug Inspection... 111 Spark Plug Recommendations ... 111 Specifications ... 145, 148 Stabilize the Fuel ... 139 Stalling While Climbing a Hill ... 30 Starting the Engine ... 72 Steering Wheel ... 37 Steering Wheel Inspection... 127 Stopping the Engine... 72 Storage ... 139 Storage Area ... 140 Switches Light Switch... 40

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Washing the Vehicle... 137 Wet Fouled Plug... 112 Wheel Installation ... 129 Wheel Removal... 129 Winch Cable Care ... 94 Winch Maintenance and Service Safety ... 96 Winch Operation ... 89 Winch Safety Precautions ... 87 Winch Shock Loading... 95

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For your nearest Polaris dealer, call 1-800-POLARIS (765-2747)

Manualsnet FAQs

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