Polaris Ranger 500 2x4, 4x4 Owner's Manual PDF

Pages 129
Year 2007
Language(s)
English en
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1 of 129

Summary of Content for Polaris Ranger 500 2x4, 4x4 Owner's Manual PDF

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

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WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners... We proudly produce an exciting line of utility and recreational products... Snowmobiles All-terrain vehicles (ATVs) RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today... Many years of experi- ence 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 should be performed only by a Factory Certified Master Service Dealer (MSD) Technician... Your Polaris dealer knows your vehicle best and is interested in your total satisfaction... Be sure to return to your dealership for all of your ser- vice needs during, and after, the warranty period... We also take great pride in our complete line of apparel, parts and acces- sories, available through our online store at www... purepolaris... com... Have your accessories and clothing delivered right to your door!

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc... Copyright 2006 Polaris Sales Inc... All information contained within this publication is based on the latest product information at the time of publication... Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited... Printed in U... S... A... 2007 RANGER 2X4/RANGER 4X4 Owners Manual P/N 9920634

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TABLE OF CONTENTS Vehicle Identification Numbers... ... ... ... ... ... ... ... ... ... ... ... ... 4 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52 Specifications... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 102 Polaris Products... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 107 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 111 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 121 Index ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 123

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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 Decals and Locations Warning decals have been placed on the vehicle for your protection... Read and follow the instructions of the decals on the vehicle carefully... If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle... If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement... Replacement safety decals are provided by Polaris at no charge... The part number is printed on the decal...

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Do not modify engine or clutch... Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death...

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IF OWNERS MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT... THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES...

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

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

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Minimum age recommendation for passengers is five years old... Passengers under five years of age require special restraints which are not available with this vehicle... Driver and passenger should wear their seat belts at all times...

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Always follow the proper procedures outlined in this manual for trav- eling 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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be properly distributed and securely attached... Reduce speed and fol- low the instructions in this manual for hauling cargo or pulling a trailer... Allow a greater distance for braking...

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

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This vehicle's tires are designed for off-road use only, not for use on pavement... Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control... Avoid operating the vehicle on pavement... If you must operate on a paved surface, travel slowly and do not make sudden turns or stops...

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The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain... All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle...

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Driving a RANGER requires your full attention... DO NOT drink alcohol or use drugs or medications before or while driving... They will reduce your alertness and slow your reaction time... In most states and provinces, it's prohibited by law to drive while intoxicated or under the influence of drugs...

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Severe injury or death can result if the vehicle and/or the operator fall through the ice... HOW TO AVOID THE HAZARD

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Travel slowly and use extra caution when operating on unfamiliar terrain... Always be alert to changing terrain conditions when operating the vehicle... You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react...

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Only persons with a valid driver's license should operate a Polaris RANGER... Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident...

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WARNING Exhaust system components are very hot during and after use of the vehicle... Hot components can cause serious burns and fire... Do not touch hot exhaust system components... Always keep combustible materials away from the exhaust system... Use caution when traveling through tall grass, especially dry grass...

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

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FEATURES AND CONTROLS Component Locations Some Polaris vehicles are equipped with special features such as the cab frame... Not all models come with all features... Refer to the specifications section beginning on page 102...

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Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch... Trailer towing equipment is not supplied with this vehicle... To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 44-47...

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Fuel Cap/Fuel Gauge The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat... It has a built-in fuel gauge that indicates the amount of fuel remaining in the tank... When the indicator needle nears the empty mark, refuel at the earliest opportunity... When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane... Do not use E-85 fuel...

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The RANGER is equipped with lap- style seat belts for the operator and passenger... To wear the seat belt properly, follow this procedure: 1... Place the belt across your lap as

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To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear... Do not attempt to shift gears with engine speed above idle or while the vehicle is moving... NOTE: Maintaining shift linkage adjustment is important to assure proper

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Throttle Pedal Push the pedal down to increase engine speed... Spring pressure returns the pedal to the rest position when released... Always check that the throttle pedal returns normally before start- ing the engine... Make sure there's adequate throttle pedal freeplay... See page 80 for throttle pedal adjustment proce- dures...

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AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/turf mode)... Press the top of the rocker switch to engage All Wheel Drive (AWD)... See page 50 for AWD operating instructions... Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD)... See page 49 for Differential Lock operating instructions... Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD)... This mode of opera- tion is well suited to turf driving or when active traction is not needed...

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OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline... No single action on your part is as important as a proper break- in period... Careful treatment of a new engine will result in more efficient performance and longer life for the engine... Perform the following pro- cedures carefully...

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WARNING If a proper inspection is not done before each use, severe injury or death could result... Always inspect the vehicle before each use to ensure it's in proper operating condition...

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NOTE: If a warm engine has cooled to a point where it does not readily start, intermittent use of the choke (half way out) may be necessary... If the engine is over-choked when warm, depress the throttle pedal fully while cranking to aid in starting... Release the throttle pedal immediately after the engine starts... If the engine does not start and all conditions are favorable, change the spark plug and try again...

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WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury... Always slow down and allow additional braking distance when towing or hauling cargo...

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vice brakes, and shift the transmission into gear... 3... Check your surroundings and determine your path of travel... 4... Release the park brake... 5... Keeping both hands on the steering wheel, slowly release the brakes

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OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding... Under these con- ditions, follow these precautions: 1... Slow down when entering slippery areas... 2... Maintain a high level of alertness, reading the trail and avoiding

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Never open the throttle suddenly... Never go over the crest of a hill at high speed... An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill...

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WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death... Avoid crossing the side of a hill when possible... When unavoidable, exercise extreme caution... Avoid operating on steep hills (15 maximum)...

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CAUTION Immersion can result in major damage if the vehicle isn't serviced correctly and promptly... After immersion, always take the vehicle to your dealer service... Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 74, and take the vehicle to your dealer at the first opportunity...

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WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle... Not all obstacles are immediately visible... Reduce speed and travel with caution in unfamiliar terrain...

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Follow these guidelines when operating in reverse: 1... Back slowly... 2... Apply the brakes lightly for stopping... 3... Avoid turning at sharp angles... 4... Always avoid backing downhill... 5... Never open the throttle suddenly while backing... 6... Always inspect left and right fields of vision before backing...

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WARNING A rolling vehicle can cause property damage and serious injury... Always engage the park brake after stopping the engine... Always block the downhill side of the wheels if leaving the vehicle on a hill, or park the vehicle in a sidehill position instead...

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USE EXTREME CAUTION when operating with loads that extend over the rack sides... Stability and maneuverability may be adversely affected, causing the vehicle to overturn... DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS... Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface... Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill...

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

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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 creating hazardous driving conditions... Never operate this vehicle with the cargo box in the raised position...

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Do not tow more than the recommended weight for the vehicle... See the towing capacity chart below and the specifications charts beginning on page 102... Attach a trailer to the trailer hitch bracket only... Do not attach a trailer to any other location or you may lose control of the vehicle...

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

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OFF/Differential Unlocked Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD)... When the rear differ- ential is unlocked, the rear wheels can rotate at different speeds... Unlock the differential to make maneuvering easier and minimize damage to turf...

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OPERATION All Wheel Drive (AWD) (4X4 Models) The illuminated amber AWD switch indicates that the vehi- cle is in AWD... When the AWD switch is on, the front gearcase will auto- matically 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... 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...

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Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition... The engine and related components must be maintained at Polaris specifications to achieve optimal performance... Engine idle speed is the only adjustment Polaris recommends that the operator perform... Any other adjustments should be performed by an authorized Polaris dealer... The emissions label is located on either the recoil cover or stator hous- ing... Remove the seat and look through the gap in the aluminum exhaust shield to view the label... NOTE: The installation of devices that effectively increase exhaust emissions

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MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition... Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart... Inspect, clean, lubricate, adjust and replace parts as necessary... When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer... Record maintenance and service in the Maintenance Log beginning on page 121... NOTE: Service and adjustments are important for proper vehicle operation... If

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WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death... Have an authorized Polaris dealer perform these services...

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Steering - Pre-Ride - Make adjustments as need ed... See Pre-Ride Checklist on page 33... Front suspension - Pre-Ride -

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Perform these procedures more often for vehicles subjected to severe use... E Emission-Related Service...

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Wiring 100 H 12 M - Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc...

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MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 52, 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...

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MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52... Always change the oil filter whenever changing oil... Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines... It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection... See page 106 for the part num- bers of Polaris products... Premium 4 possesses unsurpassed film strength over the widest possible temperature range... It resists viscosity and frictional breakdown in ambi- ent temperatures from -40 F... to 120 F... Its exceptional frictional prop- erties result in more efficient operation, more power output and lower fuel consumption... Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W- 40... Oil may need to be changed more frequently if Polaris Premium 4 is not used... Follow the manufacturer's recommendations for ambient tem- perature operation...

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MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52... We recommend the use of Polaris Premium 4 All Season Synthetic engine oil... Oil Check The oil tank is located under the seat... 1... Position the vehicle on a

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9... Reinstall the screen fitting and rotate the fitting clockwise a mini- mum of 2 1/2 turns into the tank threads... Continue to rotate the fit- ting until the nipple of the fitting aligns with the mark on the tank...

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13... Lubricate the gasket on the new filter with a film of new engine oil... Make sure the gasket is in good condition... Make sure the gasket from the old filter is not still on the engine...

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MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected... 1... Clamp or pinch off the vent line

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Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52... Maintain the oil level even with the bottom of the fill plug hole... Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications... See page 106 for the part numbers of Polaris products... Oil Check The fill plug is located at the rear of the vehicle... 1... Position the vehicle on a level

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MAINTENANCE Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission... Access the drain plug through the drain hole in the skid plate... 1... Remove the fill plug... 2... Place a drain pan under the

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MAINTENANCE Gearcases Front Gearcase (4X4) Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52... Maintain the oil level even with the bottom thread of the fill plug hole... Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications... See page 106 for the part numbers of Polaris products... Oil Check The front gearcase fill plug is located on the right side of the front gearcase... 1... Position the vehicle on a level surface... 2... Remove the fill plug... Check the oil

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MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52... Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications... See page 106 for the part numbers of Polaris lubrication products... Oil Check The rear gearcase fill plug is on the driver's side of the rear gearcase... Maintain the oil level 3/4 of an inch (19 mm) below the bottom thread of the fill plug hole... Use a light colored non-absorbent measuring instru- ment (such as a white cable tie) to measure the depth... 1... Position the vehicle on a

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Spark plug condition is indicative of engine operation... The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds... Immediately check the spark plug for correct color... See page 68...

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MAINTENANCE Spark Plugs Spark Plug Condition 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 indi- cates the proper type and heat range for the engine and the service... NOTE: The tip should not be white... A white insulator tip indicates overheating,

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MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system... The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose... As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle... As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator... NOTE: Some coolant level drop on new vehicles is normal as the system is

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MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 52... Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan... Inter- ference with the radiator air flow can lead to overheating and consequent engine damage...

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MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 52... Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan... Inter- ference with the radiator air flow can lead to overheating and consequentially, engine damage...

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When To Use Low Range vs... High Range 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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MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys- tem... Use the following instructions to dry it out before operating... 1... Loosen the bottom screws that secure the clutch cover... Allow the

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CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected... Take the vehicle to your dealer before starting the engine...

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5... Inspect the air box for oil or water deposits... If present, drain them into a suitable container... NOTE: Service the air filter more frequently if the vehicle is operated in wet

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CAUTION Operation of the vehicle without a breather filter can cause engine damage... Always reinstall the breather filter after removing it for service...

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MAINTENANCE Carburetor The idle speed adjustment should be performed as outlined in the Peri- odic Maintenance Chart, or whenever the idle speed is changed... Recom- mended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200... If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure...

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5... If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front... Engage the park brake... Block the wheels... Make sure the transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved...

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Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis- adjustment, 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 52... Adjust the freeplay if necessary...

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Cylinder Head/Cylinder Base Fastener Torque Have your dealer check the cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours...

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Brake Fluid Inspect the brake system rou- tinely... Inspect the level of the brake fluid before each opera- tion... 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... See page 57 for fluid recommenda- tions... 1... Position the vehicle on a

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

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MAINTENANCE 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 52... 1... Position the vehicle on a level surface... 2... Lightly turn the steering wheel left and right... 3... There should be 0... 8"-1... 0" (20-25 mm) of freeplay... 4... If there is excessive freeplay or strange noises, or the steering feels

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The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driv- ing... Although having the belt at 30 is typical for many peo- ple, it will not accommodate all body sizes and shapes... Make sure the seat belt is adjusted to the lowest possible lap position before riding... 1... To adjust, loosen the bolts... 2... Reposition both the buckle and retractor... Tighten the bolts... NOTE: The center belt does not self adjust... Before riding, pull on the strap to

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Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury... Always maintain proper tire pressure... When replacing tires, always use original equipment size and type...

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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... See your Polaris dealer...

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WARNING Poor lighting while driving can result in severe injury or death... Headlight and taillight lenses become dirty during normal operation... Wash the headlights frequently to maintain lighting quality...

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3... Apply the brakes... Start the engine... Turn on the headlights... 4... Observe the headlight aim... The most intense part of the headlight

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MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the console brake light comes on... Check the brake light before each ride... 1... Turn the ignition switch to the ON position... 2... Depress the brake pedal... The brake light should come on after about

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Conventional Battery 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 the battery...

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WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death... When removing the battery, always disconnect the negative (black) cable first... When reinstalling the battery, always connect the negative (black) cable last...

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MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life... It can also hinder vehicle performance... Follow the battery charging instructions on page 94 before installing the battery... 1... Ensure that the battery is fully charged... 2... Place the battery in the battery holder... 3... With conventional batteries, install the battery vent tube (sealed bat-

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MAINTENANCE Battery 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 94... NOTE: Battery charge can be maintained by using a Polaris Battery Tender

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Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installa- tion 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...

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MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of

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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

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MAINTENANCE Cleaning and Storage Washing the Vehicle 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 decals... Avoid directing the water stream at the follow- ing items: Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer

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MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a like new appearance for many years... NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)

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3... Drain the carburetor bowl... Oil and Filter Change the oil and filter... See page 60... Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter... See page 75... Clean the air box... Drain the sediment tube... Fluid Levels Inspect the fluid levels... Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 52... Front and rear gearcase fluid Transmission fluid Brake fluid (change every two years and any time the fluid looks dark

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Battery Maintenance See pages 93-95 for storage and charging procedures... Storage Area/Covers Be sure the storage area is well ventilated... Cover the vehicle with a gen- uine Polaris cover... NOTE: Do not use plastic or coated materials... They do not allow enough ven-

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Transporting the RANGER Follow these procedures when transporting the vehicle... 1... Stop the engine... 2... Remove the key to prevent loss during transporting... 3... Place the transmission in gear... 4... Engage the park brake... 5... Secure the fuel cap, oil cap and seat... 6... Always tie the frame of the RANGER to the transporting unit

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RANGER 2X4 Gross Vehicle Weight 2500 lbs... (1135 kg) Dry Weight 1105 lbs... (501 kg) Overall Length 113 in... (282 cm) Overall Width (box) 60 in... (152... 4 cm) Overall Width (tires) 58 in... (147... 3 cm) Overall Height 75 in... (190... 5 cm) Wheelbase 76 in... (193 cm) Cargo Box (L x W x H) 58 x 42 x 10 in... (147 x 106... 7 x 25... 4 cm) Ground Clearance 11... 5 in... (29 cm) Min... Turning Radius 132 in... (335... 3 cm) Fuel Capacity 9 gal... (34 l) Engine Oil Capacity 2 qts... (2... 1 l) Coolant Capacity 2... 25 qts... (2... 4 l) Towing Capacity 1500 lbs... (681 kg) Max... Cargo Box Load 850 lbs... (386 kg) Engine 4 valve 4 stroke single cylinder with

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RANGER 2X4 Lubrication System Dry Sump Engine Oil 0W/40 Driving System Type PVT Shift Type Single Lever (console) Gear Reduction - Low 8... 71:1 Gear Reduction - Reverse 5... 9:1 Gear Reduction - High 3... 83:1 Drive Ratio - Front: N/A Drive Ratio - Final 3... 70:1 Tire Size - Front 25 x 10 - 12 Tire Size - Rear 25 x 11 - 12 Tire Pressure - Front 8-12 psi Tire Pressure - Rear 8-12 psi Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Foot activated, mechanical Hood Headlight 2 dual beam, 35W, quartz/halogen Taillights 2 single beam, 5W Brake Light 2 single beam, 5W Indicator Light 1... 0 W

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RANGER 4X4 Gross Vehicle Weight 2700 lbs... (1226 kg) Dry Weight 1185 lbs... (537 kg) Overall Length 113 in... (282 cm) Overall Width (box) 60 in... (152... 4 cm) Overall Width (tires) 58 in... (147... 3 cm) Overall Height 75 in... (190... 5 cm) Wheelbase 76 in... (193 cm) Cargo Box (L x W x H) 58 x 42 x 10 in... (147 x 106... 7 x 25... 4 cm) Ground Clearance 11... 5 in... (29 cm) Min... Turning Radius 132 in... (335... 3 cm) Fuel Capacity 9 gal... (34 l) Engine Oil Capacity 2 qts... (2... 1 l) Coolant Capacity 2... 25 qts... (2... 4 l) Towing Capacity 1500 lbs... (681 kg) Max... Cargo Box Load 1000 lbs... (454 kg) Engine 4 valve 4 stroke single cylinder with

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RANGER 4X4 Lubrication System Dry Sump Engine Oil 0W/40 Driving System Type PVT Shift Type Single Lever (console) Gear Reduction - Low 8... 71:1 Gear Reduction - Reverse 5... 9:1 Gear Reduction - High 3... 83:1 Drive Ratio - Front: 3... 83:1 Drive Ratio - Final 3... 70:1 Tire Size - Front 25 x 10 - 12 Tire Size - Rear 25 x 11 - 12 Tire Pressure - Front 8-12 psi Tire Pressure - Rear 8-12 psi Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Foot activated, mechanical Hood Headlight 2 dual beam, 35W, quartz/halogen Taillights 2 single beam, 5W Brake Light 2 single beam, 5W Indicator Light 1... 0 W

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Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz... ) 2871322 Premium All Season Grease (3 oz... cartridge)

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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 flex- ible and prevent belt burning...

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Out of fuel Refuel Clogged fuel filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Inspect, clean and/or replace spark plug Low battery voltage Recharge the battery to 12... 8 VDC Mechanical failure See your dealer

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Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12... 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer

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Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect, clean and/or replace spark plug Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12... 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and core, clean

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

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HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer... When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer... (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY)... Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service... Please work with your dealer to resolve any warranty issues... Should your dealer require any additional assistance they will contact the appropriate person at Polaris... This warranty gives you specific legal rights, and you may also have other rights which vary from state to state... If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect... Lubricants 1... Mixing oil brands or using non-recommended oil may cause engine damage... We rec- ommend the use of Polaris engine oil... 2... Damage resulting from the use of non-recommended lubricants may not be covered by warranty...

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How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer... If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle... Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer... You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence... Upon residence verification, the servicing dealer will be authorized to per- form the warranty repair... If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move... Vehicles importation rules vary considerably from country to country... You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age... You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country... If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied... Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for war- ranty or service bulletin coverage of any kind... (Vehicles registered to Government offi- cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty... ) For questions call Polaris Customer Assistance: United States: 1-763-417-8650 Canada: 1-204-925-7100

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WARRANTY U... S... A... EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle... Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements... The emissions warranty period for this vehicle begins on the date the vehicle is deliv- ered to the original retail purchaser and ends 30 months (2... 5 years) after that date, or after 5000 km (3100 miles), whichever comes first... This emission-related warranty covers components whose failure would increase an engine's emissions, including electronic controls, fuel injection, exhaust-gas recircula- tion, aftertreatment, or any other system utilized in this vehicle to control emissions... Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with recommended maintenance... The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts... THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI- DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR- RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE... ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN... POLARIS DISCLAIMS ALL EXPRESS WARRAN- TIES NOT STATED IN THIS WARRANTY... Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is incon- sistent with the controlling state law... This limited warranty excludes failures not caused by a defect in material or workman- ship... This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use... This limited warranty also does not cover any engine that has been structurally altered, or any engine that has been used in racing competition... This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of Polaris... If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris Warranty Department at 1-763-417-8650...

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WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc... , 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2005 and later Large Spark Ignition Engine (herein "LSI engine")... "The California Air Resources Board has designated this engine for this vehi- cle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six (6) or four (4)-wheel drive and/or a round steering wheel... " In California, this LSI engine must be designed, built and equipped to meet the state's stringent anti-smog standards... Polaris must warrant the emission control system on your LSI engine for the period of time described below, provided there has been no abuse, neglect or improper mainte- nance of your LSI engine... Your emission control system includes parts such as the carburetor and the ignition sys- tem... Also included may be hoses, connectors and other emission-related assemblies... Where a warrantable condition exists, POLARIS will repair your LSI engine at no cost to you, including diagnosis, parts and labor... Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for two (2) years... If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS... Owner's Warranty Responsibilities: As the LSI engine owner, you are responsible for the performance of the required

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WARRANTY California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and, (2) is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below... Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date... During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the fail- ure of a warranted emission-related part... What is Covered Under This Warranty Repair and/or replacement of any warranted emission-related part will be performed at no charge provided the work is performed at an authorized dealer... There will also be no charge for any diagnostic labor performed at an authorized dealer, which leads to the determination that a warranted emission-related part is defective... Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of "repair or replace as nec- essary" shall be warranted for the warranty period... Any warranted part which is sched- uled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part... This warranty shall apply only towards the repair, replacement, and/or adjustment of the component parts listed below...

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(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)... (ii) Air/fuel ratio feedback and control system, if applicable... (iii) Cold start enrichment system, if applicable... (iv) Regulator assy (gaseous fuel, if applicable)

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WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part which malfunctions, fails or is damaged due to alterations and/or modifications such as changing, adding or removing parts... When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience... This limited warranty also does not apply to any emission-related part which malfunctions, fails, or is damaged due to failure to follow the maintenance and operating instructions specified in the 2005 and later Owner's Man- ual including: (a) Improper or inadequate maintenance of any warranted emission-related part (b) Improper installation, adjustment, or repair of the LSI engine or any warranted

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More often under severe use, such as dirty or wet conditions... Due to the nature of these adjustments, it is recommended that an authorized Polaris dealer perform service... Do not attempt to perform this work unless you are familiar with mechanical repair...

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WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty mainte- nance or repairs of emission-related parts... These replacement parts will be provided at no charge if the part is still under warranty... How to File a Warranty Claim/Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS... In the event that any emis- sion-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appro- priate dealer where the warranty repair is to be performed...

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

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Chrome Wheel Care ... ... ... ... ... ... ... ... ... ... ... ... ... 98 Cleaning and Storage ... ... ... ... ... ... ... ... 96-100 Cleaning the Air Filter ... ... ... ... ... ... ... ... ... ... ... 75 Cleaning the Exhaust System ... ... ... ... ... ... 78 Cleaning the Fuel Filter ... ... ... ... ... ... ... ... ... ... 75 Cleaning the Spark Arrestor ... ... ... ... ... ... ... 78 Component Locations ... ... ... ... ... ... ... ... ... 22-25 Condition, Spark Plugs ... ... ... ... ... ... ... ... ... ... ... 68 Console ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28 Coolant Level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70 Coolant Level, Radiator ... ... ... ... ... ... ... ... ... ... 71 Coolant, Adding or Changing... ... ... ... ... ... 69 Cooling Fan ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70 Cooling System... ... ... ... ... ... ... ... ... ... ... ... ... ... 70-71 Cooling System Operation ... ... ... ... ... ... ... ... 69 Corrosion Removal, Chrome ... ... ... ... ... ... 98 Cover for Storage ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100 Crankcase Emission Control System 51 Cylinder Head... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80

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Electromagnetic Interference... ... ... ... ... ... 51 Emission Control, Crankcase... ... ... ... ... ... 51 Emission Control, Exhaust ... ... ... ... ... ... ... 51 Emission Control, Noise ... ... ... ... ... ... ... ... ... 51 Emissions Limited Warranty ... ... ... ... ... 114 Engine Fogging ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100 Engine Idle RPM Adjustment ... ... ... ... ... 77 Engine Oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 58-62 Engine Starting ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34-35 Engine Stopping... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Equipment Modifications ... ... ... ... ... ... ... ... 13 Exhaust Cleaning ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78 Exhaust Emission Control System... ... 51 Exhaust System Warning... ... ... ... ... ... ... ... ... 78

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S Safety Decals ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5-7 Safety Symbols ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9 Seat Belt Inspection ... ... ... ... ... ... ... ... ... ... ... ... ... 84 Seat Belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27, 84 Seat Removal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26 Selector, Gear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Severe Use Definition... ... ... ... ... ... ... ... ... ... ... ... 52 Shifter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Shifting Gears ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Signal Words ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9 Spark Arrestor Warning ... ... ... ... ... ... ... ... ... ... 78 Spark Arrestor Cleaning ... ... ... ... ... ... ... ... ... ... 78 Spark Plug

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T Throttle Freeplay Adjustment ... ... ... ... ... 80 Throttle Freeplay Inspection ... ... ... ... ... ... 79 Throttle Freeplay, Freeplay, Throttle 79 Throttle Pedal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30 Throttle System ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79-80 Tire Pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5 Tire Tread Depth ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85 Tires ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85-86 Torque, Axle Nuts ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85 Torque, Spark Plug ... ... ... ... ... ... ... ... ... ... ... ... ... 67 Torque, Wheel Nut ... ... ... ... ... ... ... ... ... ... ... ... ... 85

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