Polaris Ranger 1000 Diesel, 1000 Diesel EPS, Crew 1000 v3 Manual PDF

Pages 121
Year 2017
Language(s)
English en
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1 of 121

Summary of Content for Polaris Ranger 1000 Diesel, 1000 Diesel EPS, Crew 1000 v3 Manual PDF

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We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today... Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine weve ever produced... For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer (MSD) Technician... Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction... Your POLARIS dealership can provide for all of your service needs during, and after, the warranty period...

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POLARIS, RANGER and RANGER CREW are trademarks of POLARIS Industries Inc... Copyright 2016 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... 2017 RANGER Diesel / RANGER CREW Diesel Owners Manual P/N 9927175

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TABLE OF CONTENTS Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Winch Guide ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65 Specifications... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100 POLARIS Products... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 108 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 113 Index ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 115

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INTRODUCTION The RANGER is an off-road vehicle... Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area... 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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Failure to follow the warnings contained in this manual can result in severe injury or death... Your POLARIS RANGER is not a toy and can be hazardous to operate... This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles... A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions... Read this owners manual and review the safety DVD that came with your vehicle... A free extra copy

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INTRODUCTION 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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INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997... The operating conditions of the machinery during testing: The vehicles were in like-new condition... The environment was controlled as indicated by the test procedure(s)... The uncertainty of vibration exposure measurement is dependent on many factors, including: 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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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... Approved helmets in the USA and Canada bear a U... S... Department of Transportation (DOT) label... Approved helmets in Europe, Asia and Oceania bear the ECE 22... 05 label... The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval... The approval number and serial number will also be displayed on the label...

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Rider Comfort Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger 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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SAFETY 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 any 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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terrain... Avoid paved surfaces... Avoid sidehilling (riding across slopes)... Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll, reduce your risk of injury: Keep a firm grip on the steering wheel or hand holds and brace yourself... Do not put any part of your body outside of the vehicle for any reason... LOCATE AND READ OWNERS MANUAL... FOLLOW ALL INSTRUCTIONS AND WARNINGS... ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva... org)...

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Clutch Cover Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH... Always look for and remove debris inside and around clutch and vent system when replacing belt... Read owners manual or see authorized POLARIS dealer...

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Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual... Read this entire manual and all labels carefully... Follow the operating procedures

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Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills... See page 47... 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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Equipment Modifications 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... The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non- POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power... The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle... Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle...

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Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident... The operator must understand how to operate the vehicle properly in different situations and on different types of terrain... All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle... All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www... rohva... org)...

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Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident... Always perform the pre-ride inspection before each use of your RANGER to make sure it's in safe operating condition... See page 36... Always follow all inspection and maintenance procedures and schedules described in this owner's manual... See page 65... Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation... For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle... Follow the instructions in this manual for loading, tire pressure, gear selection and speed... Do not exceed vehicle weight capacities... The vehicles maximum weight capacity is listed in the

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Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle... Hot components can cause burns and fire... Do not touch hot exhaust system components or brake system components... Always keep combustible materials away from the exhaust system... Use caution when traveling through tall grass, especially dry grass, to avoid debris build-up around the exhaust system... Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident... Always use the size and type of tires specified for your vehicle... Always maintain proper tire pressure as described in the owner's manual and on safety labels...

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SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover... Always follow proper procedures for turning as described in this owners manual... Never turn abruptly or at sharp angles... Never turn at high speeds... Practice turning at slow speeds before attempting to turn at faster speeds...

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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... Operating on Public Roads 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-highway use)...

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FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle... Cab nets (or doors, if equipped) must be used by both operator and passengers at all times... Any illustrations without cab nets are only to allow component identification... Always use the cab nets (or doors)... Not all models come with all features... Refer to the specifications section on page 100...

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Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER... High gear is intended for use on hard-packed surfaces with light loads... To shift gears, brake to a complete stop... When the engine is idling, move the lever to the desired gear... NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause

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AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD) Differential Lock (2WD) Differential Unlock Press the top of the rocker switch to engage All Wheel Drive (AWD)... See page 54 for operating instructions... Move the rocker switch to the center position to lock the differential and operate in rear wheel drive... Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate independently... See page 55 for differential lock operating instructions...

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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...

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FEATURES AND CONTROLS 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... Pull the rear edge of a seat upward to release the latch pins from the grommets... Roll the seat forward to access the under-seat area... To completely remove a seat, roll the seat forward and lift the seat tabs from the seat base mounts... Always make sure all seats are properly installed and securely latched 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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Hood Latches Remove the hood to access the coolant overflow bottle, the radiator cap and the headlight adjustment screws... To remove the hood, rotate the hood latches 1/4-turn and lift the hood away from the vehicle...

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FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928... 53 rollover performance requirements... Always have your authorized POLARIS 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... WARNING! Vehicle rollover could cause severe injury or death... Always avoid operating in a manner that could result in vehicle rollover...

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FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover... Cab nets (or doors) must be used by both operator and passengers at all times... Make sure all latches are secure before operating the vehicle... Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle... Use the strap adjusters to tighten any loose straps... Promptly replace worn or damaged cab nets and latches with new cab nets and latches... Please see your authorized POLARIS dealer...

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FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats... Always make sure the seat belts are secured for all riders before operating... WARNING! Falling from a moving vehicle could result in serious injury or death... Always fasten your seat belt securely before operating or riding in the RANGER... To wear the seat belt properly, follow this procedure: 1... For 3-point belts, pull the seat belt latch

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Rider Information Center The rider information display is located in the instrument cluster... All segments will light up for 1 second at start-up... If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer... If this occurs, your POLARIS dealer can provide proper diagnosis... 1... Vehicle Speed (Speedometer) Display - Analog display of vehicle speed in MPH or

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ON position... The lamp is a reminder to the operator to ensure all riders are wearing seat belts before operating the vehicle... The driver's 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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FEATURES AND CONTROLS Instrument Cluster Information Display Area The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock... Units of Measurement

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1-minute segment, step 4 will save the new settings and exit the clock mode... Battery Under / Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged... It may also occur when the engine is at idle and a high electrical load is applied (lights, cooling fan or other accessories)... Battery Voltage Low If battery voltage drops below 11 volts, a warning screen will display Lo and provide the present battery voltage... If voltage drops below 8... 5 volts, LCD back-lighting and icons will turn off...

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FEATURES AND CONTROLS Instrument Cluster Information Display Area Programmable Service Interval The initial factory service interval setting is 50 hours... Each time the engine is started, the engine hours are subtracted from the service interval hours... When the service interval reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started... To change the hour setting or reset the function, follow these steps: 1... Toggle the MODE button until the wrench icon is displayed in the information area... 2... Press and hold the MODE button until the information display area begins to flash... 3... Toggle the MODE button to increase the service interval hours in 5 hour increments to a

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PVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance... Break in the clutches and belt by operating at slower speeds during the break- in period as recommended... Pull only light loads... Avoid aggressive acceleration and high speed operation during the break-in period... If a belt fails, always clean any debris from the clutch air duct and from the engine compartment... See page 77...

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86 Brake fluid Ensure proper level 86 Front suspension Inspect, lubricate if necessary 68 Rear suspension Inspect, lubricate if necessary 68 Steering Ensure free operation 87 Tires Inspect condition and pressure 89 Wheels/fasteners Inspect, ensure fastener tightness 89 Frame nuts, bolts, fasteners Inspect, ensure tightness - Fuel and oil Ensure proper levels 31

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Especially in the U... S... A... and Canada, Ultra Low Sulfur fuel should be used... Bio-Diesel fuels: see pages 38-39... NEVER mix kerosene, used engine oil or residual fuels with diesel fuel... Water and sediment in the fuel should not exceed 0... 05% by volume... Keep the fuel tank and fuel-handling equipment clean at all times... Poor quality fuel can reduce engine performance and/or cause engine damage... Fuel additives are not recommended... Some fuel additives may cause poor engine

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OPERATION Fuel Recommendations Bio-Diesel Fuels In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels... KOHLER approves the use of bio-diesel fuels that do not exceed a blend of 20% (by volume) of FAME with 80% (by volume) of approved mineral oil derived diesel fuel... Such bio-diesel fuels are known in the marketplace as B20 diesel fuels... These B20 diesel fuels must meet certain requirements: 1... The bio-fuels must meet the minimum specifications for the country in which they are

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diesel blend) concentration... Operating Conditions with B20 Bio-diesel Fuel Blends Engine Warranty Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty... The same applies to damages or other concerns induced by not complying with the recommended operating conditions of KOHLER engines with bio-diesel fuel...

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Block Heater Use If this vehicle will be operated when temperatures are in the +5 to -25 F... (-15 to -32 C) range, a block heater must be installed... Please see your dealer to purchase a block heater kit... NOTE: Block heater is not recommended when the vehicle is operated above 25 F temperature...

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and cause deterioration of hoses, tubes, injectors, injector pump and seals... Use the following guidelines if bio-diesel blended fuel is used: Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle... Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in

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and avoid premature engine wear... Avoid operating in the presence of chemical gases or fumes... Avoid operating in a corrosive atmosphere such as salt water spray... NEVER operate the engine in a floodplain unless proper precautions are taken to avoid

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Stopping the Engine For maximum engine life, allow the engine to idle, without load, for 5 minutes... This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down... 1... Release the throttle pedal completely and brake to a complete stop... 2... Place the transmission in PARK... 3... Turn the engine off and remove the key to prevent unauthorized use... 4... Slowly release the brake pedal and make sure the transmission is in PARK before exiting

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2... Perform the pre-ride inspection... See page 36... 3... Sit in the driver's seat and fasten the seat belt... 4... Always use the cab nets (or doors) while riding in this vehicle... 5... Place the transmission in PARK... 6... Start the engine and allow it to warm up... 7... Apply the service brakes and shift the transmission into gear... 8... Check your surroundings and determine your path of travel... 9... Keeping both hands on the steering wheel, slowly release the brakes and slowly depress

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Driving Over Obstacles Follow these precautions when operating over obstacles: 1... Always check for obstacles before operating in a new area... 2... Look ahead and learn to read the terrain... Be constantly alert for hazards such as logs,

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Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly)... When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control... Do not operate on excessively slippery surfaces... Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1... Do not operate on excessively rough, slippery or loose terrain... 2... Slow down before entering slippery areas... 3... Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns,

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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: 1... Slow down... 2... Exercise extreme caution... 3... Avoid crossing the side of a steep hill...

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flowing water... WARNING! The large tires on your RANGER may cause the vehicle to float in deep or fast- flowing water, which could result in loss of control and lead to serious injury or death... Never cross deep or fast-flowing water with your RANGER... 5... After leaving water, always dry the brakes by applying light pressure to the pedal

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fields of vision before backing... 2... Always avoid backing downhill... 3... Back slowly... 4... Apply the brakes lightly for stopping... 5... Avoid turning at sharp angles... 6... Apply only light throttle... Never apply throttle suddenly...

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Parking on an Incline Avoid parking on an incline if possible... If it's unavoidable, follow these precautions: 1... Apply the brakes... 2... Place the transmission in PARK... 3... Turn the engine off... 4... Slowly release the brake pedal and make

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Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death... Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle... When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue... The combined weight of these items must not exceed the maximum weight capacity... REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO... Always load the cargo box with the load as far forward and as low as possible... When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions... Always operate the vehicle with extreme care when hauling or towing loads... Slow down and drive in the lowest gear available... Always use LOW gear when towing or hauling heavy loads... When transporting heavy loads and/or when towing, always operate the vehicle in low gear and have ADC activated (if equipped)... SECURE ALL LOADS BEFORE OPERATING... Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle... OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS... When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution... Always attach the tow load to the hitch point designated for your vehicle... HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS... Use extreme caution when applying brakes with a loaded vehicle... Avoid terrain or situations that may require backing downhill... USE EXTREME CAUTION when operating with loads that extend over the rack sides... Stability and maneuverability may be adversely affected, causing a rollover... DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS... Vehicle should never exceed 10 MPH (16 km/h) while towing a load on a level grass surface... Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill...

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Towing a RANGER Towing this vehicle is not recommended... Always transport the vehicle on a trailer or flatbed with all four wheels off the ground... See page 99... If towing a disabled vehicle is unavoidable, place the disabled vehicles transmission in neutral... Tow the shortest distance possible... Do not operate faster than 10 MPH (16 km/h)...

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release lever... Lift the front of the cargo box to dump the cargo... 6... Lower the cargo box and push down securely to latch... 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 could also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions... Never operate this vehicle with the cargo box in the raised position...

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OPERATION All Wheel Drive (AWD) Engaging AWD 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... See page 31... When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction... When the rear wheels regain traction, the front wheels will automatically disengage... There is no limit to the length of time the vehicle may remain in AWD... Tip: The AWD switch may be turned on or off while the vehicle is moving... Engage the AWD before getting into conditions where front wheel drive may be needed... If the rear wheels are spinning, release the throttle before switching to AWD... NOTICE: Switching to AWD while the rear wheels are spinning may cause severe drive shaft and

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Locking the differential in slippery or low traction conditions helps improve traction... Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive... Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently... This mode of operation is well suited to turf driving or whenever aggressive traction is not required...

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Winch Safety Precautions 1... Read all sections of this manual... 2... Never use alcohol or drugs before or while operating the winch... 3... Never allow children under 16 years of age to operate the winch... 4... Always wear eye protection and heavy gloves when operating the winch... 5... Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook

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possibly cause it to move without warning... 14... Never attempt to winch loads that weigh more than the winchs rated capacity... 15... The winch motor may become hot during winch use... If you winch for more than 45

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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

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WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure... For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer...

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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 62... For your safety, always follow these guidelines when winching a vehicle free: A... Release the winch clutch and spool out the necessary length of winch cable... B... Align the winch cable as close as possible to the winching vehicles centerline... C... Attach the winch cable hook to the anchor point or the stuck vehicles frame following

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15... After winching is complete, especially if winching at an angle, it may be necessary to re- distribute the winch cable across the winch drum... You will need an assistant to perform this task... A... Release the clutch on the winch... B... Feed out the winch cable that is unevenly bunched up in one area... C... Re-engage the winch clutch... D... Have an assistant pull the winch cable tightly with about 100 lbs... (45 kg) of tension using the

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WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or shock loading... Shock loading may tension a winch cable beyond its strength and cause the cable to break... The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders...

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WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH... Always follow all winch instructions and warnings in this manual...

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Operation on Public Lands in the U... S... A... Your POLARIS 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 Chart 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... Owners are responsible for performing the scheduled maintenance identified in this owners manual... Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition... Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart... Inspect, clean, lubricate, adjust and replace parts as necessary... When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer... Equivalent parts may be used for emissions-related service... Record maintenance and service in the Maintenance Log beginning on page 113... Tip: Service and adjustments are important for proper vehicle operation... If you're not familiar with safe

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Battery 25 H Monthly 200 (320) Check terminals; clean; test Air filter 25 H Monthly 200 (320) Inspect; replace as needed Front gearcase oil 25 H 1 M - Perform a break-in oil level check Transmission oil 25 H 1 M - Perform a break-in oil level check Engine oil change (break-in) 50 H - - Perform a break-in oil change Fuel System 50 H Monthly - Inspect; cycle key to pressurize fuel

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Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces Cooling Hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/pipe 100 H 12 M 1000 (1600) Inspect Drive shafts 100 H 12 M 1000 (1600) Remove and grease Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply

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Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Always change the oil filter whenever changing oil... WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury... Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart...

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MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold... If the engine is hot when the oil is checked, the level will appear to be overfull... CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components... Access the oil fill cap, dipstick and filter under the cargo box... 1... Remove all cargo from the cargo box... See page

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MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Always change the oil filter whenever changing oil... The crankcase drain plug is located on the bottom of the crankcase... Access the drain plug through the access hole in the skid plate under the crankcase (see next page)... CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components... Access the oil fill cap, dipstick and filter under the cargo box... 1... Remove all cargo from the cargo box... See page 53... 2... Position the vehicle on a level surface... 3... Place the transmission in PARK... 4... Stand clear and pull up on the cargo box release lever... Lift the front of the cargo box... 5... Locate the crankcase drain plug access hole in the skid plate... 6... Clean the area around the crankcase drain plug... CAUTION! Hot oil can cause burns to skin... Do not allow hot oil to contact skin... 7... Place a drain pan under the engine crankcase and

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cap... 14... Start the engine and check for leaks... 15... Stop the engine and wait 15 seconds before removing the dipstick... 16... Remove the dipstick... Wipe it dry with a clean cloth... 17... Reinstall the dipstick completely... Remove the dipstick and check the oil level... 18... Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the

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Oil Change The drain plug is located near the bottom of the gearcase... 1... Remove the level check/fill plug... 2... Place a drain pan under the gearcase... 3... Remove the drain plug... Allow the oil to drain completely... 4... Clean and reinstall the drain plug... Torque to specification... 5... Add the recommended oil... 6... Reinstall the fill plug... Torque to specification... 7... Check for leaks... Dispose of used oil properly...

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MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Maintain the oil level even with the bottom thread of the fill plug hole... Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications... See page 104 for the part numbers of POLARIS products...

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

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Radiator Coolant Level/Changing Procedure 1... Remove the hood... See page 26... CAUTION! Escaping steam can cause burns... Never remove the pressure cap while the engine is warm or hot... Always allow the engine to cool before removing the pressure cap... 2... Slowly remove the radiator cap... 3... View the coolant level through the opening... 4... Use a funnel and slowly add coolant as needed... Tip: This procedure is required only if the cooling system has been drained for maintenance and/or

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Do not modify any component of the PVT system... Doing so may reduce its strength so that a failure may occur at a high speed... The PVT system has been precision balanced... Any modification will cause the system to be out of balance, creating vibration and additional loads on components...

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MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt... WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death... 1... Position the vehicle on a level surface... Block the

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

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PVT Drying There may be some instances when water is accidently ingested into the PVT system... Use the following instructions to dry it out before operating... 1... Position the vehicle on a level surface... Place the transmission in PARK... Stop the engine... 2... Remove the clutch cover drain plug... Allow the

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If it's impossible to take your RANGER in for service before starting it, follow the steps outlined below... 1... Move the vehicle to dry land or at the very least, to water below the floorboard... 2... Inspect the air box for water... NOTICE: Do not attempt to start the engine if water is present in the air box... Engine damage will

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MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Service the air filter more frequently if the vehicle is operated in wet or dusty conditions or at high throttle for extended periods... 1... Lift the cargo box to access the

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can reach 1000 F... Allow components to cool sufficiently before proceeding... Remove any combustible materials from the area... Wear eye protection and gloves... Do not stand behind or in front of the vehicle while purging... Never run the engine in an enclosed area... Exhaust can cause loss of consciousness or death in a

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MAINTENANCE Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 65... Stop the machine on a flat level surface... Put the gear selector in Park, stop the engine and exit the vehicle... See page 43... 1... Raise the cargo box... 2... The belt tension is correct with

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MAINTENANCE Fuel Filter/Water Separator The fuel filter/water separator is located under the seat on the right side of the vehicle, between the engine and fuel tank... Inspect the separator daily for leaks... Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Service the separator more frequently if the vehicle is operated with inferior fuel... CAUTION! Both fuel and water will drain from the separator during the following procedure... Use caution and observe all fuel safety precautions when handling fuel... 1... Remove the seat... Disconnect the battery... 2... Place an appropriate container under the fuel filter

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Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed... The throttle may also not open fully... If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic... Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... Adjust the freeplay if necessary...

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Brake Fluid Inspect the brake system routinely... Inspect the level of the brake fluid before each operation... WARNING! After opening a bottle of brake fluid, always discard any unused portion... Never store or use a partial bottle... Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air... The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury... Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown... 1... Position the vehicle on a level surface... 2... Place the transmission in PARK... 3... View the brake fluid level at the reservoir in the drivers

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Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 65... 1... Position the vehicle on a level surface... 2... Place the transmission in PARK... 3... Lightly turn the steering wheel left and right... There should be 0... 8-1... 0 (20-25 mm) of

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MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary... 1... Remove the top shock mounting bolts from the inside mounting positions... 2... Reposition the shocks to the outside mounting holes... 3... Reinstall the shock mounting bolts... Torque to 40 ft... lbs... (54... 2 Nm)...

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Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death... Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle... Always use POLARIS-approved size and type of tires for this vehicle when replacing tires...

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WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death... Always ensure that all nuts are torqued to specification... Do not service axle nuts that have a cotter pin installed... Your POLARIS dealer can assist... 3... Attach the wheel nuts and washers and

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MAINTENANCE 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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6... If a headlight needs adjustment, locate the adjustment screw on the side of the headlight... 7... Loosen the screw... Adjust the headlight, then tighten the screw... 8... Repeat steps 5-7 until the lamp is properly adjusted...

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MAINTENANCE 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... Raise the passenger seat to access the fuses... Spare fuses are provided in the fuse box... The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box... If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer...

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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... See page 95... POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge... Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point... See page 104 for the part numbers of POLARIS products...

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MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery... Read all instructions before proceeding with the installation of this battery... The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory... Never pry the sealing strip off or add any other fluid to this battery... The single most important thing about maintaining a sealed battery is to keep it fully charged... Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage... WARNING! An overheated battery may explode, causing severe injury or death... Always watch charging times carefully... Stop charging if the battery becomes very warm to the touch... Allow it to cool before resuming charging... For a refresh charge, follow all instructions carefully... 1... Check the battery voltage with a voltmeter or multimeter... A fully charged battery will

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evaporate any water that may have entered the engine or exhaust system... If a high pressure water system is used for cleaning (not recommended), exercise extreme caution... The water may damage components and could remove paint and labels... Avoid directing the water stream at the following items:

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fogging and damage could occur... Never start the engine during the storage period... Clean the Exterior Make any necessary repairs and clean the vehicle as recommended... See page 96... Oil and Filter Change the oil and filter... See page 70... Air Filter / Air Box 1... Replace the air filter... See page 81... 2... Clean the air box...

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MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65... Battery Maintenance See page 94 for storage and charging procedures... Fluid Levels Inspect the fluid levels... Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65... Front gearcase fluid Transmission fluid Brake fluid (change every two years and any time the fluid looks dark or contaminated) Coolant (test strength/fill) Storage Area/Covers Be sure the storage area is well ventilated... Cover the vehicle with a genuine POLARIS cover... Do not use plastic or coated materials... They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation...

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are not loose... WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle... Secure or remove all cargo, and inspect the unit for loose parts prior to transport... 5... Always tie the frame of the RANGER to the transporting unit securely with suitable

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Fuel Capacity 10 gal... (37... 8 l) Engine Oil Capacity 3 qts... (2... 8 l) Coolant Capacity 5... 4 qts... (5... 11 l) Towing Capacity 2000 lbs... (907 kg) Hitch Tongue Capacity 150 lbs... (68 kg) Max... Cargo Box Load* 1000 lbs... (454 kg) Overall Length 116 in... (295 cm) Overall Width (box) 60 in... (152... 4 cm) Overall Width (tires) 58 in... (147... 3 cm) Overall Height 76 in... (193 cm) Wheelbase 81 in... (205... 7 cm) Cargo Box Dimensions (Inside) 36... 5 x 54 x 11... 5 in... (93 x 137 x 29 cm) Ground Clearance 12 in... (30... 5 cm) Min... Turning Radius 161 in... (409 cm) Engine KOHLER liquid-cooled 3 cylinder diesel Displacement 1028 cc Bore x Stroke 75mm x 77... 6mm Alternator Output 12V DC 110A Compression Ratio 22... 8:1 Starting System Electric Fuel System Mechanical fuel injection Front Suspension Dual A-arm w/10 in... (25... 4 cm) of travel Rear Suspension Independent w/10 in... (25... 4 cm) of travel Lubrication System Full pressure with full flow filter

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RANGER Diesel Driving System Type PVT, 4-wheel independent shaft, lockable differential Shift Type Single Lever (H/L/N/R/P) Transmission Gear Ratio - High Front 3... 10:1 / Rear 9... 26:1 Transmission Gear Ratio - Low Front 7... 62:1 / Rear 22... 79:1 Transmission Gear Ratio - Reverse Front 6... 83:1 / Rear 20... 41:1 Front Drive Ratio 3... 818:1 Tire Size - Front 25 x 10 - 12 (26 x 9 - 12 for select models) Tire Size - Rear 25 x 11 - 12 (26 x 11 - 12 for select models) Tire Pressure - Front 10 psi (69 kPa) Tire Pressure - Rear 12 psi (83 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L... E... D... (... 28W) Brake Light 10 L... E... D... (3... 1W)

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Fuel Capacity 10 gal... (37... 8 l) Engine Oil Capacity 3 qts... (2... 8 l) Coolant Capacity 6... 36 qts... (6... 01 l) Towing Capacity 2000 lbs... (907 kg) Hitch Tongue Capacity 150 lbs... (68 kg) Max... Cargo Box Load* 1000 lbs... (454 kg) Overall Length 148 in... (376 cm) Overall Width (box) 60 in... (152... 4 cm) Overall Width (tires) 58 in... (147... 3 cm) Overall Height 76 in... (193 cm) Wheelbase 113 in... (287 cm) Cargo Box Dimensions (Inside) 36... 5 x 54 x 11... 5 in... (93 x 137 x 29 cm) Ground Clearance 12 in... (30... 5 cm) Min... Turning Radius 214 in... (543... 5 cm) Engine KOHLER liquid-cooled 3 cylinder diesel Displacement 1028 cc Bore x Stroke 75mm x 77... 6mm Alternator Output 12V DC 110A Compression Ratio 22... 8:1 Starting System Electric Fuel System Mechanical fuel injection Front Suspension Dual A-arm w/10 in... (25... 4 cm) of travel Rear Suspension Independent w/10 in... (25... 4 cm) of travel Lubrication System Full pressure with full flow filter

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RANGER CREW Diesel Driving System Type PVT, 4-wheel independent shaft, lockable differential Shift Type Single Lever (H/L/N/R/P) Transmission Gear Ratio - High Front 3... 10:1 / Rear 9... 26:1 Transmission Gear Ratio - Low Front 7... 62:1 / Rear 22... 79:1 Transmission Gear Ratio - Reverse Front 6... 83:1 / Rear 20... 41:1 Front Drive Ratio 3... 818:1 Tire Size - Front 26 x 9 - 12 Tire Size - Rear 26 x 11 - 12 Tire Pressure - Front 14 psi (96 kPa) Tire Pressure - Rear 16 psi (110 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L... E... D... (... 28W) Brake Light 10 L... E... D... (3... 1W)

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Grease / Specialized Lubricants 2871312 Grease Gun Kit, All Season Grease 2871322 All Season Grease (3 oz... /89 ml cartridge) 2871423 All Season Grease (14 oz... /414 ml cartridge) 2876160 ATV Angle Drive Fluid (qt... /... 95 l) 2872276 ATV Angle Drive Fluid (2... 5 gal... /9... 5 l) 2871460 Premium Starter Grease 2871515 U-Joint Grease (3 oz... /89 ml cartridge) 2871551 U-Joint Grease (14 oz... /414 ml cartridge) 2871329 Dielectric Grease (Nyogel)

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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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water separator Old or non-recommended fuel Replace with fresh recommended fuel Water or fuel in crankcase Your POLARIS dealer can assist... Low battery voltage Recharge the battery to 12... 8 VDC Mechanical failure Your POLARIS dealer can assist... Defective glow plug Inspect and replace Defective stop solenoid Replace Defective fuel pump Replace

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Possible Cause Solution Poor fuel quality or incorrect fuel Replace with recommended fuel Clogged fuel filter Replace Clogged air filter Replace Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Kinked or plugged fuel tank vent line Inspect and replace Other mechanical failure Your POLARIS dealer can assist... Out of fuel Refuel Low battery voltage Recharge the battery to 12... 8 VDC Overheated engine Clean radiator screen and core, clean engine exterior,

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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 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; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center... This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

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WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies Lubricants and Fluids 1... Mixing oil brands or using non-recommended oil may cause engine damage... We recommend the use of POLARIS engine oil... 2... Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty... 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 OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... 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... THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY... ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD... POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY... SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW...

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WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer... When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer... (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY... ) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service... In the Country where your product was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer... If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product... Outside the Country where your product was purchased: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer... You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence... Upon residence verification, the servicing dealer will be authorized to perform the warranty repair... If you move: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move... 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... If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied... You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product...

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CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (ARB), U... S... Environmental Protection Agency (EPA) and Kohler Co... are pleased to explain the emission control system warranty on your MY 2014-2016 engine... In California (the State) and U... S... EPA regulated applications, new heavy-duty off-road engines must be designed, built and equipped to meet the States and the U... S... EPAs stringent anti-smog standards... Kohler Co... must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine... Your emission control system may include parts such as the fuel injection system and the air induction system... Also included may be hoses, belts, connectors and other emission-related assemblies... Where a warrantable condition exists, Kohler Co... will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor...

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WARRANTY COVERAGE Kohler Co... will repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts... The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co... Emission control system parts/components covered by the Federal and California Emission Control Systems Limited Warranty are listed below... Fuel injector(s) Injection pump(s) Exhaust manifold Intake manifold Exhaust gas recirculation (EGR) tube Crankcase ventilation valve Electronic control unit (ECU) if equipped Sensors associated with ECU operation Emission control information labels Turbocharger (if equipped) Fuel limiting device Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under the warranty provisions for a period of time up to the first scheduled replacement point for the subject parts/components... Subsequent damage to other engine components as a direct result of a warrantable failure on an exhaust emission part/component will be covered under the warranty provisions described herein... As the heavy-duty off-road engine owner, you should however be aware that Kohler may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications... Only due to the above reasons, the manufacturer may deny warranty coverage...

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

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D Differential Lock Switch ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23 Differential Locking ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55 Disengaging AWD ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54 Display, Information... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32-34 Drive Belt Wear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105 Drivetrain Break-In... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Driving Downhill ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47 Driving in Reverse ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49 Driving on a Sidehill... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47 Driving on Slippery Surfaces ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46 Driving Over Obstacles ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 Driving Procedure... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44 Driving Through Water ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48 Driving Uphill... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47 Driving with a Passenger ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 Driving, After Driving in Water ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Drying the Transmission... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Dumping the Cargo Box... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 53

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P Parking on an Incline... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50 Parking the Vehicle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50 Part Numbers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104 Periodic Maintenance Chart ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65-67 Plug, Accessory ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22 Plugs, Spark ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 74 Polaris Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104 Polishing the Vehicle... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97 Power Steering... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24 Power Steering Unit (Cleaning) ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90 Pre-Ride Inspection ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36 Product Part Numbers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104 Programmable Service Interval ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 Public Lands ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64 PVT Break-In ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 PVT Drying ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 PVT System... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76-79 PVT Warning... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76 PVT, Cleaning Debris ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77-79

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Shifter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22 Shifting Gears ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22 Shock Loading the Winch... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 62 Shock Spring Adjustment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88 Signal Words... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Spark Arrester Warning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82 Spark Plugs ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 74 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100-103 Specifications, Gearcase ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 72 Speed, Towing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52 Speedometer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30-34 Spring, Shock, Adjustment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88 Starting the Engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43 Steering Wheel Inspection ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87 Steering Wheel, Adjustment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24 Stopping the Engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43 Storage ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96-98 Storage Area ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98 Storage Compartment, Under-Seat ... ... ... ... ... ... ... ... ... ... ... ... 25 Storage, Battery ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94 Storage, Covers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98 Storage, Fluid Levels ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98 Storage, Oil and Filter... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97 Storage, Removal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99 Suspension Adjustment, Rear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88 Switches

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On excessively steep hills... On public roads (unless designated for off-road use)... With a passenger who is not seated in a passenger seat, or with passengers

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