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

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

WARNING

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

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.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

Engine Serial Number

VIN

Key Number

####

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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.

Container/Passenger/Tire Pressure Warning WARNING

Remove flammable material containers from box before filling. Passengers can be thrown off. This

can cause serious injury or death.

Never carry passengers in cargo box.

Maximum 2X4 Box Load 850 lbs. Maximum 4X4 Box Load 1000 lbs.

Maximum 6X6 Box Load 1200 lbs.

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): RANGER - 2X4 and 4X4 FRONT 10 REAR 10

RANGER - 6X6 FRONT 10 CENTER 10 REAR 10 MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO:

RANGER 2X4 and 4X4 is 2750 LBS. RANGER 6X6 is 2900 LBS. Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box.

Read Owner's Manual for more detailed loading information.

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SAFETY Safety Decals and Locations

Clutch Cover Warning WARNING NO STEP

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

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.

Cab Frame/Seat Belt Warning WARNING VEHICLE ROLLOVER could cause severe injury or death. This cab frame is

not designed or intended to provide rollover protection.

ALWAYS WEAR YOUR SEAT BELT for maximum protection.

Cab Frame/Seat Belt Warning

Clutch Cover Warning

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SAFETY Safety Decals and Locations Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle.

Discretionary Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

Operate on public roads. A collision can occur with a another vehicle.

Carry more than two passengers, or passengers under age five.

Use ALCOHOL or DRUGS before or while operating this vehicle.

Operate at speeds too fast for your skills or the conditions.

Operate this vehicle on HILLS steeper than 15 degrees 15. To prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS: Avoid paved surfaces which may adversely affect handling and control.

Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns.

Wear eye protection. REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sharp turns.

The park/emergency brake lever will supply increased braking, but should be used as an emergency or parking brake only.

READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

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.

Shift Caution

Discretionary Warning

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SAFETY Operator Safety

Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger in this vehicle.

Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable 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.

WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating the vehicle.

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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.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION A caution indicates a situation that may result in damage to the vehicle.

NOTE: A note will alert you to important information or instructions.

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SAFETY Operator Safety

Read this manual and all labels carefully. Follow the operating procedures described.

Never allow anyone without a valid driver's license to operate this vehicle.

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

Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels.

To reduce tipover risk, be especially careful when encountering obstacles and slopes and when braking on hills or during turns.

This vehicle is for off road use only. Never operate on public roads. Always avoid paved surfaces.

Helmets are recommended whenever driving this vehicle in an aggressive manner. Eye protection is recommended at all times.

Never consume alcohol or drugs before or while operating this vehicle.

Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

Never attempt jumps or other stunts. Always inspect your vehicle each time you use it to make sure it's in

safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation.

Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

Never operate on excessively rough, slippery or loose terrain.

WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

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SAFETY Operator Safety Always follow proper procedures for turning as described in this

manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident.

Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

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.

Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such as rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skid- ding or sliding out of control.

Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stop- ping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on page 5 and in the specifications section beginning on page 102.

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SAFETY Operator Safety Never modify this vehicle through improper installation or use of

accessories. Never exceed the stated load capacity for this vehicle. Cargo should

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.

Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.

Always keep arms and legs inside the cab frame while the vehicle is in motion.

Always engage the park brake before getting out of the vehicle. See page 30.

Always apply the brakes before releasing the park brake. Always turn off the engine before refueling. Make sure the refueling

area is well ventilated and free of any source of flame or sparks. Gas- oline is extremely flammable. See page 21 for fuel safety warnings.

Always remove the ignition key when the vehicle is not in use to pre- vent unauthorized use or accidental starting.

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

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SAFETY Operator Safety

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-

ers, 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.

WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

Do not make any modifications to your RANGER.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Stalling, rolling backwards while climbing a hill

WHAT CAN HAPPEN Vehicle overturn

HOW TO AVOID THE HAZARD

Maintain a steady speed when climbing a hill. If you lose all forward speed:

Apply the brakes.

Engage the park brake after fully stopped. If you begin rolling backwards:

Never apply engine power.

Apply the brakes gradually. When fully stopped, engage the park brake.

In the event of an accident, have a qualified service dealer check the complete vehicle for possible damage, including (but not limited to) brakes, throttle and steering.

WARNING POTENTIAL HAZARD

Operating this vehicle on paved surfaces

WHAT CAN HAPPEN Loss of control

HOW TO AVOID THE HAZARD

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

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Operating this vehicle without proper instruction

WHAT CAN HAPPEN Loss of control, accident

HOW TO AVOID THE HAZARD

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

WARNING POTENTIAL HAZARD

Operating this vehicle on public streets, roads or highways

WHAT CAN HAPPEN

Collision with another vehicle HOW TO AVOID THE HAZARD

Never operate this vehicle on any public street, road or highway, including dirt or gravel.

In many states it's illegal to operate vehicles of this type on public streets, roads and highways.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Operating this vehicle after consuming alcohol or drugs

WHAT CAN HAPPEN Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD

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

WARNING POTENTIAL HAZARD

Operating this vehicle at excessive speeds WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Attempting jumps and other stunts

WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn

HOW TO AVOID THE HAZARD

Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING POTENTIAL HAZARD Operating on frozen bodies of water

WHAT CAN HAPPEN

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

Never operate the RANGER on a frozen body of water.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Failure to inspect the vehicle before operating

Failure to properly maintain the vehicle WHAT CAN HAPPEN

Accident, equipment damage

HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual.

WARNING POTENTIAL HAZARD

Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN

Loss of control, vehicle overturn

HOW TO AVOID THE HAZARD

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

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD

Failure to follow the minimum age recommendations for this vehicle

WHAT CAN HAPPEN Serious injury or death (the child or others)

HOW TO AVOID THE HAZARD

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

WARNING POTENTIAL HAZARD

Operating this vehicle with improper tires or with improper or uneven tire pressure

WHAT CAN HAPPEN

Loss of control, accident and/or overturn HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the Owner's Manual for this vehicle. Always maintain proper tire pressure as described on the decal and in the Owner's Manual. See pages 5 and 102.

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SAFETY Operator Safety

WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

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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SAFETY Fuel Safety

WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

Always stop the engine when refueling.

Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.

Do not over fill the tank. Do not fill the tank neck.

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

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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.

Cab Frame (if Equipped)

Console

Steering Wheel

Hip Bar

Seat Storage Box

(under drivers seat)

Cargo Box Seat Belt

Battery (under hood)

Fuel Tank Cap

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FEATURES AND CONTROLS Component Locations

Headlights

Hood Hold-Down

Strap Front Bumper/Brush Guard

Radiator (if equipped)

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FEATURES AND CONTROLS Component Locations

Tailgate Latch Release

Taillights

Air Box

Receiver Hitch

CV Boot/Rear Caliper

Muffler (Spark Arrestor)

Taillights

Tailgate

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FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console. See page 28.

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.

Auxiliary Outlet The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood.

High Gear

Low Gear (if equipped)

Neutral Gear

Reverse Gear

High Temperature

Brakes

Auxiliary Outlet

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FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

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.

Fuel Cap

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FEATURES AND CONTROLS Seat Belts

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

low on your hips as possible. Make sure that the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self tighten. NOTE: The center belt must be tightened manually by pulling on the strap.

4. To release the seat belt, press the square red button in the buckle's center.

WARNING Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER.

Passengers under five years of age require special restraints, which are not available with this vehicle. No person under the age of five may ride in the RANGER.

Seat Belt

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FEATURES AND CONTROLS Console

Indicator Lights AWD/Differential

SwitchCup Holder

Cup Holder

Storage Compartment

(with lid)

12V Accessory

Outlet Storage

Tray

Ignition SwitchStorage

Box

Light Switch

Gear Selector (Shifter)

Choke Knob

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FEATURES AND CONTROLS Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary

driving range for the RANGER. High gear is intended for use on hard- packed surfaces with light loads.

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

transmission function. See your dealer if you experience any shifting problems.

CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Gear Selector

H

L

N

R

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FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.

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.

Park Brake Pedal Engage the park brake when parking the vehicle to help prevent the vehicle from rolling. To engage the park brake, apply the brakes, then push the park brake pedal down firmly and fully with your foot.

Park Brake Release Always apply the service brakes before releasing the park brake. To release the park brake, pull the park brake release handle. Make sure the park brake pedal is functioning properly before each operation.

Park Brake Pedal

Park Brake Release

Throttle Pedal

Brake Pedal

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FEATURES AND CONTROLS Switches

Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has three positions: high beam, low beam and off.

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.

OFF The engine is off. Electrical circuits are off, except Acc, 12V.

ON Electrical circuits are on. Electrical equipment can be used.

START Turn the key to the START position to engage the electric starter. The key returns to the ON position when released.

WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use

Ignition Switch

Light Switch

AWD/ Differential

Switch

High Beam

Low Beam

OFF

AWD

2WD

OFF

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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.

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 21.

2. Check the oil level. See page 59. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to famil- iarize yourself with vehicle operation and handling.

4. Vary throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 33. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at 25

hours.

CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

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OPERATION Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 30 81

Brake fluid Ensure proper level 81

Front suspension Inspect, lubricate if necessary 57

Rear suspension Inspect, lubricate if necessary 57

Steering Ensure free operation 83

Tires Inspect condition and pressure 5 85

Wheels/fasteners Inspect, ensure fastener tightness 85

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 26 59

Coolant level Ensure proper level 70 71

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 79

Indicator lights/switches Ensure operation 25

Air filter, pre-filter Inspect, clean 75

Air box sediment tube Drain deposits whenever visible 75

Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced

87

Brake light/tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced

89

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OPERATION Starting the Engine

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

2. Engage the park brake.

3. Shift the transmission to neutral.

4. Apply the brakes. NOTE: Do not use the

choke if starting a warm engine. Excessive use of the choke can cause spark plugs to become wet fouled.

5. If the engine is cold, pull the choke knob out until it stops. 6. Turn the ignition key past the ON/RUN position to START. Engage

the starter for a maximum of five seconds. Release the key when the engine starts.

NOTE: Do not press the throttle pedal while starting the engine.

7. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Repeat steps 6 and 7 until the engine starts.

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.

WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

Choke Knob

FULL ON

HALF ON

OFF

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OPERATION Starting the Engine 8. After the engine starts, push the choke knob in half way. 9. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly. 10. Push the choke knob in.

Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Engage the park brake.

Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you're familiar

with the controls.

NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.

CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine.

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.

36

OPERATION Driving Safely Driving Procedure

1. Sit in the driver's seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the ser-

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

and depress the throttle with your right foot to begin driving. 6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces. NOTE: Low gear is the primary range for operating the RANGER. High gear is

intended for use on hard-packed surfaces with light loads.

37

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

quick, sharp turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the

skid. 4. Drive with AWD engaged (if equipped) to assist in controlling the

vehicle..

CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution when operating on slippery surfaces.

38

OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel

straight uphill. 2. Avoid steep hills

(15 maximum). 3. Keep both feet on

the floor. 4. Proceed at a

steady rate of speed and throttle opening.

WARNING Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill.

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (15 maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual.

Never climb hills with excessively slippery or loose surfaces.

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

15 maximum

39

OPERATION Driving Safely Driving on a Sidehill (Sidehilling)

Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brakes slightly to aid in slowing.

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).

WARNING Traveling downhill improperly could cause loss of control or vehicle overturn. Always check the terrain carefully before descending a hill.

Never descend a hill at high speed. Excessive speed may result in loss of vehicle control and lead to serious injury or death. Always operate slowly when traveling downhill.

Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible.

40

OPERATION Driving Safely Driving Through Water

Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floor- boards. Follow these procedures when oper- ating through water: 1. Always determine

water depths and current before entering.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles. 4. After leaving water, always dry the brakes by applying light pres-

sure to the pedal repeatedly until braking action is normal. NOTE: After running your vehicle in water, it's critical that you perform the ser-

vices outlined in the Periodic Maintenance Chart beginning on page 52. Give special attention to engine oil, transmission oil, front and rear gearcases, and all grease fittings.

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.

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.

Floorboard

41

OPERATION Driving Safely Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches.

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

42

OPERATION Driving Safely Driving in Reverse

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

WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual. Always back slowly.

43

OPERATION Driving Safely Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side.

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

Operating the vehicle while the park brake is engaged could cause loss of control and result in serious injury or death. Always disengage the park brake before operating the vehicle.

44

OPERATION Driving Safely Hauling Cargo

WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

Always load the cargo box with the load as far forward and as low as possible.

When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

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

45

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.

Model Maximum Capacities (Level Ground)

Cargo Box

RANGER 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg)

RANGER 2X4 1350 lbs. (613 kg) 850 lbs. (386 kg)

WARNING Driving with passengers in the cargo box can result in severe injury or death.

Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.

46

OPERATION Driving Safely Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Engage the park brake.

3. Dismount the vehicle. 4. Ensure that the cargo

is positioned evenly or toward the front of the cargo box.

5. Release the tailgate by pulling up on the tailgate latch. 6. Stand clear and pull up on the cargo box release lever. 7. Lift the front of the cargo box to dump the cargo. 8. 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 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.

WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders.

Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

Release Lever

47

OPERATION Driving Safely Towing Loads

Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than the recommended vertical tongue weight on the towing bracket.

Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 44. Towing a trailer increases braking distance.

Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the specifications charts beginning on page 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.

Never tow a trailer on a grade steeper than 15.

Model Total Towed Load Weight

(Level Ground)

Total Towed Load Weight (15 grade)

Total Hitch Vertical Weight

Maximum Towing Speed

RANGER 4X4 1500 lbs. (681 kg)

850 lbs. (386 kg)

150 lbs. (68.1 kg)

10 mph (16 km/h)

RANGER 2X4 1500 lbs. (681 kg)

850 lbs. (386 kg)

150 lbs. (68.1 kg)

10 mph (16 km/h)

48

OPERATION Driving Safely Parking the Vehicle

1. Stop the vehicle on a level surface. 2. Turn the engine off. 3. Engage the park brake. 4. Remove the ignition switch key to prevent unauthorized use.

WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine.

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.

49

OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. On 4X4 models, engaging AWD locks the front differential and the rear differential.

AWD (4X4) Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed. See page 50 for AWD operating instructions.

2WD/Rear Differential Locked Move the rocker switch to the center position to lock the differential and oper- ate in two wheel drive (2WD). Locking the differential in slippery or low traction conditions helps improve traction. When the rear differential is locked, both rear wheels rotate at the same speed.

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.

CAUTION Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

50

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.

Disengaging AWD Under certain conditions, it may be possible for the front gearcase to remain locked unnecessarily. This condition causes increased steering effort and some vehicle speed restriction. If the front gearcase remains locked after following these instructions, return the vehicle to your dealer for service. 1. Stop the vehicle. 2. Operate in reverse for at least 10 feet. 3. Stop completely. 4. Shift into low gear and drive forward.

CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage. Always switch to AWD while the rear wheels have traction or are at rest.

AWD Switch

51

EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of off-road vehicles on public lands in the U.S.A. Is regulated by 43 CFR 8343. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System 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

beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle.

Electromagnetic Interference This spark ignition system complies with Canadian ICES-002. This vehicle complies with European directives 97/24/EC and 89/336/ EEC.

52

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

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten (10) miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank- case. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

53

MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key

Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California)

Have an authorized Polaris dealer perform these services.

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.

54

MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.

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

Have an authorized Polaris dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

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

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake pedal travel

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

E Engine oil level - Pre-Ride -

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

as needed

Air box sediment tube

- Daily - Drain deposits when visible

Coolant (if applicable)

- Daily - Check level daily, change coolant every 2 years

Headlamp/tail lamp

- Daily - Check operation; apply dielectric grease if replacing

E Air filter, main element

- Weekly - Inspect; replace as needed

Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

Front Gearcase Oil (if equipped)

25 H Monthly - Inspect level; change yearly

Middle Gearcase Oil (if equipped)

25 H Monthly - Inspect level; change yearly

Rear gearcase oil (if equipped)

25 H Monthly - Inspect level; change yearly

Transmission oil 25 H Monthly - Inspect level; change yearly

55

MAINTENANCE Periodic Maintenance Chart

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

Have an authorized Polaris dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

E Engine breather filter (if equipped)

20 H Monthly - Inspect; replace if necessary

E Engine oil change (break-in)

25 H 1 M - Perform a break-in oil change at one month

General lubrication

50 H 3 M - Lubricate all fittings, pivots, cables, etc.

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

Steering 50 H 6 M - Lubricate

Front Suspension 50 H 6 M - Lubricate

Rear Suspension 50 H 6 M - Lubricate

Carburetor float bowl

50 H 6 M - Drain bowl periodically and prior to storage

E Throttle cable 50 H 6 M - Inspect; adjust; lubricate;

replace if necessary

E Choke cable 50 H 6 M - Inspect; adjust; lubricate;

replace if necessary

E Carburetor air intake ducts/flange

50 H 6 M - Inspect ducts for proper seal- ing/air leaks

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

Cooling system (if applicable)

50 H 6 M - Inspect coolant strength seasonally; pressure test system yearly

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

at one month

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

E Oil tank vent hose 100 H 12 M - Inspect routing, condition

E Valve clearance 100 H 12 M - Inspect; adjust

56

MAINTENANCE Periodic Maintenance Chart

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

Have an authorized Polaris dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

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

lines, fuel valve, filter, pump, carburetor; replace lines every two years

Fuel filter 100 H 12 M - Replace yearly

Radiator (in applicable)

100 H 12 M - Inspect; clean external surfaces

Cooling Hoses 100 H 12 M - Inspect for leaks

Engine mounts 100 H 12 M - Inspect

Exhaust muffler/ pipe

100 H 12 M - Inspect

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

E Ignition timing 100 H 12 M - Inspect

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

Clutches (drive and driven)

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

Front wheel bearings

100 H 12 M - Inspect; replace as needed

Brake fluid 200 H 24 M - Change every two years

Spark arrestor 300 H 36 M - Clean out

Idle speed - Adjust as needed

Toe adjustment - Inspect periodically; adjust when parts are replaced

Auxiliary brake (if equipped)

- Inspect daily; adjust as needed

Headlight aim - Adjust as needed

57

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.

.

Item Lube Method Engine Oil Polaris Premium 4 Synthetic

0W40 See page 59.

Brake Fluid DOT 3 or DOT 4 See page 81.

Main Gearcase Oil (Transmission)

Premium AGL Synthetic Gearcase Lube

See page 63.

Front Gearcase Oil Premium Demand Drive Hub Fluid

See page 65.

Rear Gearcase Oil Premium ATV Angle Drive Fluid

See page 66.

Prop Shaft U-joints Polaris Premium U-Joint Lube

Locate fittings and grease. See above.

Front Prop Shaft Yoke (4X4)

Polaris Premium U-Joint Lube

Locate fittings and grease (3 pumps maximum).

Ball Joint Polaris Premium all Season Grease or grease conform- ing to NLGI No. 2

Locate fitting (back side of struts), grease with grease gun.

Swing Arm Bushings

Polaris Premium all Season Grease or grease conform- ing to NLGI No. 2

Locate fittings on swing arm and grease with grease gun.

4X4 Prop Shaft U-Joint

58

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.

CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified "SH" oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40.

WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.

59

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

level surface. 2. Apply the brakes. Start the

engine and allow it to idle for 20-30 seconds. Stop the engine.

3. Remove the seat. See page 26.

4. Remove the dipstick. Wipe it dry with a clean cloth.

5. Reinstall the dipstick. Screw it in completely.

NOTE: The dipstick must be screwed in completely to keep the angle and depth of the stick consis- tent.

Remove the dipstick. Make sure that the oil level is between the full and add marks. Add oil if necessary. Do not overfill. NOTE: A rising oil level between checks in cool weather driving can indicate

moisture collecting in the oil reservoir. If the oil level is above the full mark, change the oil.

Add

{Safe Range

Full

60

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 52. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level

surface. 2. Run the engine for two to

three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath oil tank.

5. Remove the drain plug. Allow the oil to drain com- pletely.

6. Install a new sealing washer on the drain plug.

NOTE: The sealing surfaces on drain plug and oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

8. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting.

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape.

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.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34 Nm).

CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.

Sealing Washer

Drain Plug

Screen Fitting

Orientation Mark

61

MAINTENANCE Engine Oil Oil and Filter Change 10. Reattach the oil line. 11. Place shop towels beneath

the oil filter. Using an oil fil- ter wrench, turn the filter counterclockwise to remove it.

12. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase.

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.

14. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

15. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crank- case.

NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

16. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). 17. Remove the dipstick and fill the tank with two quarts (1.9 l) of the

recommended oil. 18. Place the gear selector in neutral and engage the parking brake. 19. Prime the oil pump using the procedure on page 62. Then stop

the engine and inspect for leaks. 20. Check the oil level on the dipstick. Add oil as necessary to bring the

level to the upper mark on the dipstick. 21. Dispose of used filter and oil properly.

Oil Filter

62

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

approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should hear a rush of air, indicating that the line is properly primed and ready for operation.

NOTE: If you do not hear air, the line has not bled. Repeat the priming proce- dure.

Clamp

Pressure Relief Slit

Tank 2"

(5 cm)

63

MAINTENANCE Gearcases Gearcase Specification Chart

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

surface. 2. Remove the fill plug. 3. Check the oil level. 4. Add the recommended oil as

needed. 5. Reinstall the fill plug. Torque

to specification.

Gearcase Lubricant Capacity Fill Plug Torque

Drain Plug Torque

Main Gearcase (Transmission)

(4X4)

Premium AGL Synthetic

Gearcase Lube

15.2 oz. (450 ml)

14 ft. lbs. (19.4 Nm)

14 ft. lbs. (19.4 Nm)

Main Gearcase (Transmission)

(2X4)

Premium AGL Synthetic

Gearcase Lube

18.2 oz. (540 ml)

14 ft. lbs. (19.4 Nm)

14 ft. lbs. (19.4 Nm)

Front Gearcase (4X4)

Premium Demand Drive Hub Fluid

5 oz. (150 ml)

8-10 ft. lbs. (11-13.6 Nm

11 ft. lbs. (15 Nm)

Rear Gearcase (2X4, 4X4)

Premium ATV Angle Drive Fluid

18 oz. (532 ml)

40-50 ft. lbs. (54-68 Nm

30-45 in. lbs. (3-5 Nm)

Fill Plug

64

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

drain plug. 3. Remove the drain plug. Drain

the oil. 4. Wipe the magnetic end of the

drain plug clean to remove accumulated metallic filings.

5. After the oil has drained completely, install a new sealing washer.

NOTE: Refer to the Gearcase Specifications Chart on page 63 for recom- mended lubricants, capacities and torque specifications.

6. Reinstall the drain plug. Torque to specification. 7. Add the recommended oil as needed. Do not overfill. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Dispose of used oil properly.

Drain Plug

65

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

level. 3. Add the recommended oil as needed. 4. Reinstall the fill plug. Torque to spec-

ification. Oil Change 1. Support the vehicle securely with a

jackstand. 2. Remove the front tire on the driver's

side. 3. Remove the fill plug. 4. Place a drain pan under the drain plug on the bottom right-hand

side. 5. Remove the drain plug. Drain the oil. 6. Clean the drain plug. Reinstall the drain plug. Torque to specifica-

tion. 7. Add the recommended oil. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Discard used oil properly.

Drain Plug

Fill Plug

66

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

level surface. 2. Remove the fill plug. Check

the oil level. 3. Add the recommended oil

as needed. 4. Reinstall the fill plug.

Torque to specification. Oil Change 1. Remove the fill plug. 2. Place a drain pan under the

drain plug. 3. Remove the drain plug. Drain

the oil. 4. Clean the drain plug. Reinstall

the drain plug. Torque to specification.

5. Add the recommended oil. 6. Reinstall the fill plug. Torque to specification. 7. Check for leaks. 8. Dispose of used oil properly.

Fill Plug

Drain Plug

67

MAINTENANCE Spark Plugs

Spark Plug Gap/Torque

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.

CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102.

Model Electrode Gap New Plug Torque

Used Plug Torque

RANGER 4X4 RANGER 2X4

.036" (.9 mm) 9-11 ft. lbs. (12-15 Nm)

9-11 ft. lbs. (12-15 Nm)

WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

68

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,

caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect throt- tle body/carburetor adjustments.

Spark Plug Removal and Replacement 1. Remove the seat to access the engine compartment. 2. Remove the spark plug cap. Using the spark plug wrench provided

in the tool kit, remove the plug by rotating it counterclockwise. 3. Reverse the procedure for spark plug installation. Torque to specifi-

cation. See page 67.

69

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

purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 106 for the part numbers of Polaris prod- ucts. NOTE: Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Any time the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

70

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.

Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The overflow bottle is located in front of the right front wheel. 1. Position the vehicle on a level surface. 2. View the coolant level in the overflow

bottle. 3. If the coolant level is below the safe

operating range, lift the hood and locate the overflow bottle lid. Remove the lid and use a funnel to add coolant through the filler opening. Reinstall the cap.

NOTE: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer.

CAUTION Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a high-pressure system is not recommended.

Overflow Bottle

71

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.

1. Lift the hood. 2. Slowly remove the radi-

ator cap. 3. View the coolant level

through the opening. 4. Use a funnel and slowly

add coolant as needed. NOTE: This procedure is

required only if the cooling system has been drained for maintenance and/or repair. But if the over- flow bottle has run dry, the level in the radiator should also be inspected.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. See your dealer for the correct replacement part.

WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

Radiator Cap

72

MAINTENANCE Polaris Variable Transmission (PVT) System

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.).

WARNING Failure to comply with the instructions in this warning can result in severe injury or death.

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

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual.

This PVT system is intended for use on Polaris products only. Do not install it in any other product.

Always make sure the PVT housing is securely in place during operation.

Condition Range to Use

Operating at speeds less than 7 MPH (11 km/h) Low

Towing heavy loads Low

Operating in rough terrain (swamps, mountains, etc.) Low

Operating at speeds greater than 7 MPH (11 km/h) High

73

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

water to drain. Tighten the screws. 2. Apply the brakes. Start the engine. Engage the park brake. Shift the

transmission to neutral. 3. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed. Apply the service brakes. Release the park brake and shift the transmission to the low- est available range.

5. Test for belt slippage. If the belt slips, repeat the process. 6. Take the vehicle to your dealer for service as soon as possible.

74

MAINTENANCE Vehicle Immersion

If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below. 1. Move the vehicle to dry land or

at the very least, to water below the footrests.

2. Disconnect the fuel pump wires. 3. Remove the spark plug. 4. Place a clean container under

the engine and loosen the carbu- retor drain screw two turns.

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

6. Inspect the drained fuel for water or sediment.

7. Dry the spark plug and reinstall it, or install a new plug.

8. Tighten the carburetor drain screw. 9. Reconnect the fuel pump wires. 10. Attempt to start the engine. If necessary, repeat the drying proce-

dure. 11. Take the vehicle to your dealer for service as soon as possible,

whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT follow the procedure on page

73 for drying.

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.

Drain Screw

75

MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. 1. Lift the cargo box to

access the air box. 2. Remove the air box

cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.

3. Remove the air filter. 4. Do not attempt to clean

the main element. Install a new air filter.

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.

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

conditions or at high throttle openings for extended periods.

Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter.

Air Filter

76

MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and

locate the air box. 2. Follow the right-hand

breather line out the side of the air box and locate the filter.

3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace as needed.

4. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall the filter with the arrow pointing toward the engine. Secure the clamps.

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

Breather Line Breather Filter

77

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.

Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is unsatisfactory and all other conditions are favorable, the carbu- retor can be adjusted. 1. Engage the park brake. 2. Shift the transmission to neutral. 3. Start the engine and allow it to warm

up for approximately five minutes. 4. Remove the seat. Locate the idle

adjust screw. 5. Place the transmission in gear. 6. Turn the screw in (clockwise) to raise

RPM. Turn the screw out (counter- clockwise) to lower RPM.

Idle Adjust Screw

78

MAINTENANCE Spark Arrestor

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out

plugs located on the bottom of the muffler.

2. Shift the transmission to neutral. Apply the brakes. Start the engine.

3. Purge accumulated carbon from the system by momentarily rev- ving the engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet and rap on the pipe around the clean-out plugs while revving the engine several more times.

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

6. Stop the engine. Allow the arrestor to cool. 7. Reinstall the arrestor plugs and remove the outlet cover or plug.

WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 F. Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and gloves.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time. Never go under the vehicle while it's inclined.

Clean-Out Plugs

Exhaust Outlet

79

MAINTENANCE Throttle System

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.

Throttle Freeplay Inspection 1. Engage the park brake. Shift the transmission to neutral. 2. Apply the brakes. Start the engine. Allow it to warm up thoroughly. 3. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.6- 3.2 mm).

WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.

Always check the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.

Throttle Pedal

Park Brake

80

MAINTENANCE Throttle System Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable

adjuster. 3. Squeeze the end of the rub-

ber boot and slide it far enough to expose the end of the inline cable adjuster.

4. Loosen the adjuster lock nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 79.

NOTE: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut. 7. Squeeze the end of the rubber boot and slide it over the cable

adjuster to its original position.

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.

Boot

Adjuster Lock Nut

81

MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30.

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

level surface. 2. View the brake fluid level at

the reservoir under the hood. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the lower level line, add brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

Brake Fluid Reservoir

82

MAINTENANCE Brakes Brake Inspection 1. Check the brake system for

fluid leaks. 2. Check the brake pedal for

excessive travel or a spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. Inspect the brake disc spline and pad wear surface for excessive wear.

5. Change pads when worn to 3/64" (1 mm).

Park Brake Inspection 1. Slowly push the park brake

pedal down with your foot. 2. After 8 to 12 clicks of pedal

travel, check the vehicle for movement. The vehicle should not roll while parked. If the vehicle moves, adjust the park brake.

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

as needed.

3/64" (1mm)

Park Brake Pedal

83

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

rough or "catchy," have the steering system inspected by an autho- rized Polaris dealer.

Suspension Adjustment The rear suspension may be adjusted to provide a stiffer suspension if necessary. 1. Remove the top shock mounting bolts from the inside mounting

holes. 2. Reposition the shocks to the outside mounting holes. 3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension.

Outside Mounting Holes

Inside Mounting Holes Cam

84

MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate

must slide smoothly into the buckle. A click indicates that it's securely latched.

2. Push the red button in the middle of the buckle to make sure it releases freely.

3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before 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

secure the belt on the lap of the center passenger.

WARNING Failure to follow the age recommendations for this vehicle could result in serious injury or death. No one under the age of 16 may operate this vehicle. No one under the age of 5 may ride as a passenger in this vehicle.

Bolts

85

MAINTENANCE Tires

Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service.

NOTE: Do not lubricate the stud or the lug nut.

WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less.

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

Nut Type Location Nut Torque

Lug Nut Front and Rear 90 ft. lbs. (122 Nm)

2-Piece Flange Nut

Front and Rear 35 ft. lbs. (47 Nm)

Spindle Nut Front 70 ft. lbs. (95 Nm)

Hub Retaining Nuts Center and Rear 110 ft. lbs. (150 Nm)

1/8" (3 mm)

86

MAINTENANCE Tires

Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park

brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the

frame. 4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation 1. Place the transmission

in gear. 2. Engage the park

brake. 3. Place the wheel in the

correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota- tion.

4. Attach the wheel nuts and washers and finger tighten. 5. Carefully lower the vehicle to the ground. 6. Torque the wheel nuts to specification. See page 85.

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.

87

MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement 1. Open the hood. 2. Unplug the headlamp from

the wiring harness. Be sure to pull on the connector, not on the wiring.

3. Turn the lamp counter- clockwise to remove it.

4. Install the new lamp. NOTE: Make sure the tab on the

lamp locates properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

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

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently.

Wiring Harness

88

MAINTENANCE Lights Headlight Beam Adjustment

1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

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

beam should be aimed 8" (20 cm) below the mark placed on the wall in step 2.

NOTE: Include the weight of a rider on the seat while performing this step.

5. If the headlight needs adjustment, open the hood.

NOTE: The lights are part of the hood assembly.

6. Turn the adjustment screw to adjust the beam.

7. Close the hood and repeat steps 4-6 until the lamp is properly adjusted.

25 ft. (7.6 m)

8" (20 cm) XX

Adjustment Screw

View of drivers headlight with hood lifted.

89

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

10mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb.

Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console

panel and lift the release to unplug the light from the harness.

3. Using a flathead screwdriver, press on the tab on the top of the light to remove the indi- cator light assembly from the console panel.

4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4 turn counterclockwise.

5. Grip the lamp with a needle-nose pliers and remove it from the assembly.

6. Install the new lamp. Using a screwdriver, rotate the lamp 1/4 turn clockwise to seat it.

7. Snap the assembly back into the console panel. Reconnect the har- ness.

8. Close the hood.

Tab Release

90

MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

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.

WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote: External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

91

MAINTENANCE Battery

Battery Removal 1. Open the hood. 2. On conventional batteries,

remove the battery vent tube. 3. Disconnect the black (nega-

tive) battery cable first. 4. Disconnect the red (positive)

battery cable last. 5. Lift the battery out of the

vehicle. Be careful not to tip a conventional battery side- ways, which could spill elec- trolyte.

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.

CAUTION If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

Battery

92

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-

teries do not have a vent tube). NOTE: The vent tube must be free of obstructions and securely installed.

Route the tube away from the frame and vehicle body to prevent con- tact with electrolyte.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first. 6. Connect and tighten the black (negative) cable last. 7. Verify that cables are properly routed.

WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

93

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

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 106 for the part numbers of Polaris products.

Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the bat- tery fluid level often. Maintain the fluid level between the upper and lower level marks. Add only distilled water. Tap water contains minerals that are harmful to a battery.

Lower Mark

Upper Mark

94

MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 91. 2. Charge the battery with a charging output no larger than 1/10 of the

batterys amp/hr rating. Charge as needed to raise the specific grav- ity to 1.270 or greater.

3. Reinstall the battery. See page 92. Make sure the positive terminal is toward the front of the vehicle.

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.

For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until battery voltage is 12.8 or greater. NOTE: When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging.

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.

95

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

charging.

State of Charge

Voltage Action Charge Time

(Using constant current charger @ standard amps specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no charge given,

check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

verify state of charge

0%-25% 11.5 volts or less Needs charge with desulfating charger

At least 20 hours

96

MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components.

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots.

Washing Tips Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the finish.

CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

97

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

for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips Avoid the use of automotive products, some of which can scratch the

finish of your vehicle. Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the finish.

98

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)

are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol- ished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as out- lined above.

99

MAINTENANCE Cleaning and Storage Storage Tips

Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 96. Stabilize the Fuel 1. Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or

Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.

NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust sys- tems.

2. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor.

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

or contaminated) Coolant (test strength/fill) Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52.

CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

100

MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons of Premium 4 Syn-

thetic 0W40 engine oil. 2. Reinstall the spark plug. Torque to specification. See page 67. 3. Apply dielectric grease to the inside of the spark plug cap. Reinstall

the cap. 4. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protec- tive film of fresh oil.

5. Treat the fuel system with Polaris Carbon Clean. See page 99. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

6. To eliminate any fuel remaining in the carburetor, run the engine until it stops.

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-

tilation to prevent condensation, and may promote corrosion and oxi- dation.

101

MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces-

sary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way.

2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section

on page 33. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by

an authorized Polaris dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 52.

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

securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area.

102

SPECIFICATIONS

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

counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42.5 Main Jet 135 Needle Jet P-6 (829) Jet Needle 4MB32-3 Air Screw 2.5 Alternator Output 250 W Compression Ratio 10.2:1 Starting System Electric Carburetor 34 mm CV Mikuni Ignition System CDI Ignition Timing 30 @5000 RPM Spark Plug NGK BKR5E Front Suspension MacPherson strut w/8 in. (20 cm) of travel Rear Suspension Independent w/9 in. (23 cm) of travel

103

SPECIFICATIONS

NOTE: See your Polaris dealer for jetting and clutching specifications.

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

104

SPECIFICATIONS

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

counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42.5 Main Jet 135 Needle Jet P-6 (829) Jet Needle 4MB32-3 Air Screw 2.5 Alternator Output 250 W Compression Ratio 10.2:1 Starting System Electric Carburetor 34 mm CV Mikuni Ignition System CDI Ignition Timing 30 @5000 RPM Spark Plug NGK BKR5E Front Suspension MacPherson strut w/8.25 in. (21 cm) of travel Rear Suspension Independent w/9 in. (23 cm) of travel

105

SPECIFICATIONS

NOTE: See your Polaris dealer for jetting and clutching specifications.

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

106

POLARIS PRODUCTS Part Number Description

Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

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

Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.)

2873603 Premium AGL Synthetic Gearcase Lube (gal.)

2871653 Premium ATV Angle Drive Fluid (8 oz.) 2872276 Premium ATV Angle Drive Fluid (2.5 gal.)

2870465 Pump for Gallon Jug

2871654 Premium Demand Drive Hub Fluid (8 oz.) 2872277 Premium Demand Drive Hub Fluid (2.5 gal.)

Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.)

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

2871423 Premium All Season Grease (14 oz. cartridge)

2871460 Starter Drive Grease (2 oz.) 2871515 Premium U-Joint Lube (3 oz.)

2871551 Premium U-Joint Lube (14 oz.)

2871329 Dielectric Grease (NyogelTM) 2872073 Chain Lube, Aerosol (6.25 oz.)

2872348 Chain Lube, Aerosol (16 oz.)

Additives / Miscellaneous 2872889 Brake and Clutch Cleaner

2871326 Carbon Clean Plus (12 oz.)

2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid

2870990 DOT 3 Brake Fluid

2872893 Engine Degreaser (12 oz.) 2871956 LoctiteTM 565 Thread Sealant

2871076 Polaris Battery TenderTM Charger

107

TROUBLESHOOTING Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Use low range during loading.

Starting out going up a steep incline

Use low range. See warnings on page 38.

Driving at low RPM or ground speed (3-7 MPH)

Drive at a higher speed or use low range more frequently. See page 72.

Insufficient warm-up at low ambient tempera- tures

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.

Slow/easy clutch engage- ment

Use the throttle quickly and effectively.

Towing/pushing at low RPM/low ground speed

Use low range only.

Utility use/plowing Use low range only. Stuck in mud or snow Shift the transmission to low range and carefully use fast,

aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the PVT system

Dry out the PVT. See page 73. Inspect clutch seals for damage if repeated leaking occurs.

Clutch malfunction See your Polaris dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer. Slippage from failure to warm up belt

Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

Wrong or missing belt Install the recommended belt. Improper break-in Always break in a new belt and/or clutch. See pages 32

and 72.

108

TROUBLESHOOTING Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Possible Cause Solution

Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Tripped circuit breaker Reset the breaker

Possible Cause Solution

Out of fuel Refuel Clogged fuel filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with 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

Possible Cause Solution

Weak spark from spark plug Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel

109

TROUBLESHOOTING Engine Pings or Knocks

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Possible Cause Solution

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

Possible Lean Fuel Cause Solution

Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer

Possible Rich Fuel Cause Solution

Overuse of choke Inspect, clean and/or replace spark plug Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer

110

TROUBLESHOOTING Engine Stops or Loses Power

Possible Cause Solution

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

engine exterior, see your dealer

111

WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This war- ranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.

REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trou- ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, 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.

112

WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi- tations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

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

SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require- ments of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations.

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WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military per- sonnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Recalls.

How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to per- form the warranty repair. If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age. You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country. 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

114

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.

115

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

maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you retain all receipts covering maintenance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the LSI engine owner, you should, however, be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris Warranty Department at 1-763-417-8650.

116

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.

117

WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System

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

(2) Air Induction System (i) Intake manifold, if applicable (ii) Air filter

(3) Ignition System (i) Spark plugs (ii) Magneto or electronic ignition system (iii) Spark advance/retard system, if applicable

(4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems

(i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assy (gaseous fuel, if applicable)

If an authorized dealer determines that other LSI engine components have been dam- aged due to the failure of a warranted emission-related part during the warranty period, POLARIS will repair and/or replace the necessary components.

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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

emission-related part unless performed by an authorized dealer (c) Failure to use recommended fuel as specified in the 2005 and later Owner's Manual (d) Repairs and diagnosis performed outside of an authorized dealer (e) Use of parts which are not authorized by POLARIS

Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and mainte- nance services performed at the intervals specified in the 2005 and later Owner's Manual and to retain records of these services as having been performed. These records should be transferred to each subsequent owner of the LSI engine. POLARIS cannot deny a claim solely because there are no records of scheduled maintenance, however, a war- ranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission-related part. As a minimum, the LSI engine owner is responsible for the scheduled inspection and maintenance described below which are based on the procedures described in the Owner's Manual.

119

WARRANTY California Emission Control Warranty Statement NOTE:

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.

Maintenance Schedule

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Air filter, pre-cleaner

- Daily - Inspect; clean

Air filter, main element

- Weekly - Inspect; replace if necessary

Engine breather filter

20 H Monthly - Inspect; replace annually and as needed

Engine oil, level/ change

100 H 6 M - Check level daily; break-in service at 1 month. Change oil more often in cold weather use.

Oil filter 100 H 6 M - Replace with oil change

Engine breather hose

100 H 6 M - Inspect

Choke (enricher) cable

50 H 6 M - Inspect; adjust; lubricate; replace if necessary

Spark plug 100 H 12 M - Inspect; replace if necessary

Ignition timing 100 H 12 M - Inspect and adjust as needed

Fuel system 100 H 12 M - Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years

Valve clearance 100 H 12 M - Inspect; adjust

Idle speed As required Adjust

120

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.

The Air Index of this Engine is 3

Least CleanMost Clean 0 2 4 6 8 10

Note: The lower the Air Index, the less pollution. This engine is certified to be emission compliant for 1000 hours of use.

121

MAINTENANCE LOG Use the following chart to record periodic maintenance.

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

122

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

123

INDEX A

Adding Coolant. . . . . . . . . . . . . . . . . 69 Adjustment

Headlight Beam . . . . . . . . . . . . 88 Park Brake. . . . . . . . . . . . . . . . . 82 Rear Spring . . . . . . . . . . . . . . . . 83 Rear Suspension . . . . . . . . . . . . 83 Throttle Freeplay. . . . . . . . . . . . 80

Age Restrictions . . . . . . . . . . . . . . . . . 8 Air Filter . . . . . . . . . . . . . . . . . . . . . . 75 Air Filter Cleaning . . . . . . . . . . . . . . 75 All Wheel Drive . . . . . . . . . . . . . . . . 50 All Wheel Drive Lock Switch . . . . . 31 Arrestor, Spark, Warning . . . . . . . . . 78 Auxiliary Outlet . . . . . . . . . . . . . . . . 25 AWD. . . . . . . . . . . . . . . . . . . . . . . . . 50 AWD/Differential Lock Switch . . . . 31 Axle Nut Torque . . . . . . . . . . . . . . . . 85

B Battery . . . . . . . . . . . . . . . . . . . . 90-95

Charging (Conventional) . . . . . 94 Charging (Sealed Battery) . 94-95 Conventional . . . . . . . . . . . . . . . 90 Fluid Replenishment . . . . . . . . . 93 Installation . . . . . . . . . . . . . . . . 92 Removal . . . . . . . . . . . . . . . . . . 91 Storage . . . . . . . . . . . . . . . . . . . 93

Beam Adjustment, Headlight . . . . . . 88 Before Riding . . . . . . . . . . . . . . . . . . 33 Belt Burning . . . . . . . . . . . . . . . . . . 107 Belt Life . . . . . . . . . . . . . . . . . . . . . . 47 Belt Wear . . . . . . . . . . . . . . . . . . . . 107 Belts, Seat . . . . . . . . . . . . . . . . . . 27, 84 Brake

Fluid . . . . . . . . . . . . . . . . . . . . . 81 Inspection . . . . . . . . . . . . . . . . . 82 Lights . . . . . . . . . . . . . . . . . . . . 89 Pedal . . . . . . . . . . . . . . . . . . . . . 30 Park . . . . . . . . . . . . . . . . . . . . . . 30 Park Brake Adjustment . . . . . . . 82

Braking . . . . . . . . . . . . . . . . . . . . . . . 35 Break-In Period. . . . . . . . . . . . . . . . . 32 Breather Filter . . . . . . . . . . . . . . . . . . 76 Burning Belts . . . . . . . . . . . . . . . . . 107

C Capacity, Weight . . . . . . . . . . . . . . . 45 Carburetor . . . . . . . . . . . . . . . . . . . . . 77 Carburetor Adjustment . . . . . . . . . . . 77 Cargo. . . . . . . . . . . . . . . . . . . . . . 44-45 Cargo Box, Dumping . . . . . . . . . . . . 46 Changing Coolant . . . . . . . . . . . . . . . 69 Changing Gears. . . . . . . . . . . . . . . . . 29

C Changing Oil

Engine . . . . . . . . . . . . . . . . . . . . 60 Front Gearcase . . . . . . . . . . . . . 65 Rear Gearcase . . . . . . . . . . . . . . 66 Transmission/Main Gearcase . . 64

Chart, Gearcase Specifications . . . . . 63 Chart, Periodic Maintenance . . . 52-56 Checking Oil

Engine . . . . . . . . . . . . . . . . . . . . 59 Front Gearcase . . . . . . . . . . . . . 65 Rear Gearcase . . . . . . . . . . . . . . 66 Transmission/Main Gearcase . . 63

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

D Definition, Severe Use . . . . . . . . . . . 52 Depth, Tread . . . . . . . . . . . . . . . . . . . 85 Differential Lock Switch . . . . . . . . . 31 Differential Operation. . . . . . . . . . . . 49 Disengaging AWD . . . . . . . . . . . . . . 50 Drive Belt Wear . . . . . . . . . . . . . . . 107 Driving Downhill . . . . . . . . . . . . . . . 39 Driving in Reverse . . . . . . . . . . . . . . 42 Driving on a Sidehill. . . . . . . . . . . . . 39 Driving on Slippery Surfaces . . . . . . 37 Driving Over Obstacles . . . . . . . . . . 41 Driving Procedure. . . . . . . . . . . . . . . 36 Driving Safely. . . . . . . . . . . . . . . 36-48 Driving Through Water . . . . . . . . . . 40 Driving Uphill. . . . . . . . . . . . . . . . . . 38 Driving, After Driving in Water . . . . 73 Drying the Transmission. . . . . . . . . . 73 Dumping the Cargo Box. . . . . . . . . . 46

124

INDEX E

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

F Fan, Cooling . . . . . . . . . . . . . . . . . . 70 Fastener, Cylinder Head/Base . . . . . 80 Filling the Battery . . . . . . . . . . . . . . 93 Filter

Air . . . . . . . . . . . . . . . . . . . . . . 75 Breather . . . . . . . . . . . . . . . . . . 76 Care During Storage . . . . . . . . 99 Change . . . . . . . . . . . . . . . . . . . 60 Cleaning, Air . . . . . . . . . . . . . . 75 Cleaning, Fuel . . . . . . . . . . . . . 75 Fuel . . . . . . . . . . . . . . . . . . . . . 75 Systems . . . . . . . . . . . . . . . . 75-76

Fluid Levels During Storage . . . . . . 99 Fluid, Battery . . . . . . . . . . . . . . . . . . 93 Fluid, Brake . . . . . . . . . . . . . . . . . . . 81 Fogging the Engine . . . . . . . . . . . . 100 Fouled Plugs . . . . . . . . . . . . . . . . . . 68 Freeplay Adjustment, Throttle. . . . . 80 Freeplay, Steering Wheel. . . . . . . . . 83 Front Gearcase

Lubrication. . . . . . . . . . . . . . . . 65 Oil Change . . . . . . . . . . . . . . . . 65 Oil Check. . . . . . . . . . . . . . . . . 65

Fuel Cap. . . . . . . . . . . . . . . . . . . . . . 26 Filter. . . . . . . . . . . . . . . . . . . . . 75 Gauge. . . . . . . . . . . . . . . . . . . . 26 Safety . . . . . . . . . . . . . . . . . . . . 21 Stabilizer . . . . . . . . . . . . . . . . . 99

G Gap, Spark Plug . . . . . . . . . . . . . . . . 67 Gear Selector . . . . . . . . . . . . . . . . . . 29 Gearcase

Lubrication. . . . . . . . . . . . . . . . 63 Specification Chart . . . . . . . . . 63

G Gearcases . . . . . . . . . . . . . . . . . . . 63-66 Gears, shifting . . . . . . . . . . . . . . . . . . 29

H Hauling a Load . . . . . . . . . . . . . . 44-45 Hauling Cargo . . . . . . . . . . . . . . . 44-45 Headlight Beam Adjustment . . . . . . . 88 Headlight Lamp Replacement . . . . . . 87 Hitch Weight . . . . . . . . . . . . . . . . . . . 47

I Idle RPM Adjustment . . . . . . . . . . . . 77 Ignition Switch . . . . . . . . . . . . . . . . . 31 Indicator Light Replacement . . . . . . . 89 Indicator Lights . . . . . . . . . . . . . . . . . 25 Inspection

Axle Nuts. . . . . . . . . . . . . . . . . . 85 Brakes . . . . . . . . . . . . . . . . . . . . 82 Park Brake . . . . . . . . . . . . . . . . . 82 Pre-Ride . . . . . . . . . . . . . . . . . . . 33 Seat Belts . . . . . . . . . . . . . . . . . . 84 Steering Wheel . . . . . . . . . . . . . 83 Throttle Freeplay . . . . . . . . . . . . 79 Wheel Nuts . . . . . . . . . . . . . . . . 85

Installation, Battery . . . . . . . . . . . . . . 92 Installation, Wheels . . . . . . . . . . . . . . 86 Interference, Electromagnetic . . . . . . 51

K Key, Periodic Maintenance Chart . . . 53

L Lamp Replacement, Headlight . . . . . 87 Lamp Replacement, Indicator Lights 89 Level, Coolant . . . . . . . . . . . . . . . 70-71 Life of Belt. . . . . . . . . . . . . . . . . . . . . 47 Light Switch . . . . . . . . . . . . . . . . . . . 31 Lights . . . . . . . . . . . . . . . . . . . . . . 87-89 Lights, Brake . . . . . . . . . . . . . . . . . . . 89 Lights, Indicator. . . . . . . . . . . . . . . . . 25 Load Capacity . . . . . . . . . . . . . . . . . . 45 Loads, Towing . . . . . . . . . . . . . . . . . . 47 Lubricant Part Numbers. . . . . . . . . . 106 Lubrication

For Storage . . . . . . . . . . . . . . . . 99 Recommendations . . . . . . . . . . . 57 Front Gearcase. . . . . . . . . . . . . . 65 Gearcase. . . . . . . . . . . . . . . . . . . 63 Main Gearcase . . . . . . . . . . . . . . 63 Rear Gearcase . . . . . . . . . . . . . . 66 Transmission . . . . . . . . . . . . . . . 63

125

INDEX M

Main Gearcase Lubrication . . . . . . . . . . . . . . . . 63 Oil Change . . . . . . . . . . . . . . . . 64 Oil Check . . . . . . . . . . . . . . . . . 63

Maintenance Log . . . . . . . . . . 121-122 Maintenance, Periodic . . . . . . . . 52-56 Modifications . . . . . . . . . . . . . . . . . . 13

N Noise Emission Control System . . . . 51

O Obstacles . . . . . . . . . . . . . . . . . . . . . . 41 Oil and Filter Care During Storage. . 99 Oil and Filter Change . . . . . . . . . 61-62 Oil Change

Engine . . . . . . . . . . . . . . . . . . . . 60 Front Gearcase . . . . . . . . . . . . . 65 Main Gearcase . . . . . . . . . . . . . 64 Rear Gearcase . . . . . . . . . . . . . . 66 Transmission . . . . . . . . . . . . . . . 64

Oil Check Engine . . . . . . . . . . . . . . . . . . . . 59 Front Gearcase . . . . . . . . . . . . . 65 Main Gearcase . . . . . . . . . . . . . 63 Rear Gearcase . . . . . . . . . . . . . . 66 Transmission . . . . . . . . . . . . . . . 63

Oil Pump Priming . . . . . . . . . . . . . . . 62 Oil, Engine . . . . . . . . . . . . . . . . . 58-62 Oil, Synthetic . . . . . . . . . . . . . . . . . . 58 Operation on Public Lands . . . . . . . . 51 Operation, Cooling System. . . . . . . . 69 Operation, Transmission . . . . . . . . . . 72 Operator Safety . . . . . . . . . . . . . . . 8-20 Outlet, Auxiliary . . . . . . . . . . . . . . . . 25

P Park Brake

Adjustment . . . . . . . . . . . . . . . . 82 Inspection . . . . . . . . . . . . . . . . . 82 Release . . . . . . . . . . . . . . . . . . . 30

Parking on an Incline . . . . . . . . . . . . 43 Parking the Vehicle. . . . . . . . . . . . . . 48 Periodic Maintenance Chart . . . . 52-56 Plug

Condition . . . . . . . . . . . . . . . . . 68 Gap . . . . . . . . . . . . . . . . . . . . . . 67 Torque. . . . . . . . . . . . . . . . . . . . 67 Fouled . . . . . . . . . . . . . . . . . . . . 68 Spark Plug. . . . . . . . . . . . . . . . . 67

Polaris Products . . . . . . . . . . . . . . . 106

P Polishing the Vehicle . . . . . . . . . . . . 97 Premium 4 Synthetic Oil . . . . . . . . . 58 Pre-Ride Inspection . . . . . . . . . . . . . 33 Pressure, Tire . . . . . . . . . . . . . . . . . . . 5 Public Lands . . . . . . . . . . . . . . . . . . . 51 PVT Drying . . . . . . . . . . . . . . . . . . . 73 PVT System . . . . . . . . . . . . . . . . . . . 73 PVT System Operation . . . . . . . . . . . 72

R Radiator. . . . . . . . . . . . . . . . . . . . . . . 70 Radiator Coolant Level. . . . . . . . . . . 71 Rear Gearcase

Lubrication . . . . . . . . . . . . . . . . 66 Oil Change . . . . . . . . . . . . . . . . 66 Oil Check . . . . . . . . . . . . . . . . . 66

Rear Spring Adjustment . . . . . . . . . . 83 Rear Suspension Adjustment . . . . . . 83 Release, Park Brake . . . . . . . . . . . . . 30 Removing the Vehicle from Storage 101 Replacement, Headlight Lamp . . . . . 87 Reverse . . . . . . . . . . . . . . . . . . . . . . . 42

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

Condition . . . . . . . . . . . . . . . . . 68 Gap . . . . . . . . . . . . . . . . . . . . . . 67 Removal . . . . . . . . . . . . . . . . . . 68 Torque. . . . . . . . . . . . . . . . . . . . 67 Recommendations. . . . . . . . 67-68 Fouled . . . . . . . . . . . . . . . . . . . . 68

Specifications . . . . . . . . . . . . . 102-105 Specifications, Gearcase . . . . . . . . . . 63 Speed, Towing . . . . . . . . . . . . . . . . . 47 Spring, Rear, Adjustment . . . . . . . . . 83 Stabilizing the Fuel . . . . . . . . . . . . . . 99 Starting the Engine . . . . . . . . . . . 34-35 Steering Wheel Inspection . . . . . . . . 83 Stopping the Engine . . . . . . . . . . . . . 35

126

INDEX S

Storage . . . . . . . . . . . . . . . . . . . . 96-100 Storage and Inspection. . . . . . . . . . . 99 Storage and Lubrication. . . . . . . . . . 99 Storage

Area . . . . . . . . . . . . . . . . . . . . 100 Battery . . . . . . . . . . . . . . . . . . . 93 Covers . . . . . . . . . . . . . . . . . . 100 Fluid Levels . . . . . . . . . . . . . . . 99 Oil and Filter . . . . . . . . . . . . . . 99 Removal From . . . . . . . . . . . . 101

Suspension Adjustment, Rear . . . . . 83 Switch, AWD/Differential Lock . . . 31 Switch, Ignition . . . . . . . . . . . . . . . . 31 Switch, Light . . . . . . . . . . . . . . . . . . 31 Switches. . . . . . . . . . . . . . . . . . . . . . 31 Synthetic Oil . . . . . . . . . . . . . . . . . . 58

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

T Towing Loads . . . . . . . . . . . . . . . . . . 47 Towing Speed . . . . . . . . . . . . . . . . . . 47 Trailer Hitch Bracket . . . . . . . . . . . . . 25 Transmission

Lubrication. . . . . . . . . . . . . . . . . 63 Oil Change. . . . . . . . . . . . . . . . . 64 Oil Check. . . . . . . . . . . . . . . . . . 63 Operation . . . . . . . . . . . . . . . . . . 72 System . . . . . . . . . . . . . . . . . . . . 73 Drying . . . . . . . . . . . . . . . . . . . . 73

Transporting the Vehicle . . . . . . . . . 101 Tread Depth . . . . . . . . . . . . . . . . . . . . 85

V Vehicle Break-In . . . . . . . . . . . . . . . . 32 Vehicle Identification Numbers. . . . . . 4 Vehicle Immersion . . . . . . . . . . . . . . 74 Vehicle Transport . . . . . . . . . . . . . . 101

W Warning Symbols . . . . . . . . . . . . . . . . 9 Washing the Vehicle . . . . . . . . . . 96, 97 Water, Immersion of Vehicle . . . . . . 74 Wear, Drive Belt . . . . . . . . . . . . . . . 107 Weight Capacity . . . . . . . . . . . . . . . . 45 Weight, Hitch. . . . . . . . . . . . . . . . . . . 47 Wheel Installation . . . . . . . . .

Manualsnet FAQs

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