Contents

Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual PDF

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Summary of Content for Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual PDF

OWNERS MANUAL

For Maintenance and Safety

RANGER 500 RANGER 570 RANGER CREW 570

2021

WARNING Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

! 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.

For videos and more information about a safe riding experience with

your Polaris vehicle, scan this QR Code with your smartphone.

!

2021 Owners Manual

RANGER 500 RANGER 570

RANGER CREW 570

Unless noted, trademarks are the property of Polaris Industries Inc.

Recreational Off-Highway Vehicle Association and ROHVA are registered trademarks of Recreational Off-Highway Vehicle Association.

BatteryMINDer is a registered trademark of VDC Electronics Inc.

Loctite is a registered trademark of Henkel Corporation.

NYOGEL is a registered trademark of Nye Lubricants, Inc.

WD-40 is registered to WD-40 Manufacturing Company.

QR Codes is a registered trademark of DENSO WAVE INCORPORATED.

Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A. 9931254 R01

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products. We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine weve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during and after the warranty period.

For the most up-to-date owners manual visit https://www. polaris. com/en-us/ owners-manuals.

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WELCOME

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

DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING WARNING indicates a hazardous situation which, if not avoided, COULD result

in death or serious injury.

CAUTION CAUTION indicates a hazardous situation which, if not avoided, COULD result

in minor to moderate injury.

NOTICE

NOTICE provides key information by clarifying instructions.

IMPORTANT IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

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SAFETY SYMBOLS AND SIGNALWORDS

IMPORTANT ISRAEL MODEL INFORMATION . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . 9 Safety . . . . . . . . . . . . . . . . . . . . . . 13 Features and Controls . . . . . . . . . . . . . . 35 Operation . . . . . . . . . . . . . . . . . . . . 55 Winch Guide. . . . . . . . . . . . . . . . . . . 75 Emission Control Systems . . . . . . . . . . . . . 87 Maintenance . . . . . . . . . . . . . . . . . . 89 Specifications . . . . . . . . . . . . . . . . . . 133 POLARIS Products . . . . . . . . . . . . . . . . 139 Troubleshooting . . . . . . . . . . . . . . . . . 141 Warranty . . . . . . . . . . . . . . . . . . . . 145 Maintenance Log . . . . . . . . . . . . . . . . 155

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6

IMPORTANT ISRAEL MODEL INFORMATION ISRAEL MODEL DIFFERENCES

IMPORTANT Israel models are different in important ways from the other models covered by

this owners manual. The unique characteristics of Israel models are not referenced throughout the rest of this owners manual. If you are using an Israel model, carefully read the statements below and keep them in mind

before consulting the rest of the owners manual.

ISRAEL MODELS ARE TWO- PERSON VEHICLES.

Israel models are designed to accommodate two individuals - a driver and a passenger. Do not operate Israel models with more than one passenger, as there are only two seat belts available for use. Disregard all mentions of passengers in the manual text if you are using an Israel model.

ISRAEL MODELS ARE NON- TRACTOR VEHICLES.

Israel models have not completed testing to be certified as tractors. Disregard all mentions of tractor in the manual text if you are using an Israel model.

SEATADJUSTMENT NOTE The text in the Seat Adjustments section (in the Features and Controls chapter) does not apply to Israel models. Disregard the text in the Seat Adjustments section if you are using an Israel model.

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IMPORTANT ISRAEL MODEL INFORMATION

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INTRODUCTION BEFORE YOU RIDE This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

WARNING

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

routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read this owners manual and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.

Never operate this vehicle without proper instruction. Take an authorized training course. See the Safety Training section for more information.

This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid drivers license to operate this vehicle.

Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other body parts inside the vehicle at all times.

Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

Never operate this vehicle under the influence of drugs or alcohol, as these conditions impair judgement and the operators ability to react.

Complete the New Operator Driving Procedures outlined in this manual. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures.

Never permit a guest to operate this vehicle unless the guest has reviewed the owners manual and all safety labels and has completed a safety training

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INTRODUCTION

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

q Vehicle Identification Number (VIN) w Engine Serial Number

Vehicle Model Number:

Vehicle Identification Number (VIN):

Engine Serial Number:

Key Number

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INTRODUCTION

EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

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

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INTRODUCTION

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SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course.

ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751.

Your POLARIS vehicle is considered 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 vehicle are thoroughly inspected at specific intervals.

For more information about recreational off-road vehicle safety in the United States, visit www.rohva.org, call 949-255-2560 or call POLARIS at 800-342-3764.

SAFE RIDING GEAR Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury.

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SAFETY

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

Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow.

q Helmet w Eye Protection e Long Sleeves t Long Pants r Gloves y Over-the-Ankle Boots

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SAFETY

HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

Parents and supervising adults should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

GLOVES Wear gloves for comfort and for protection from sun, cold weather and other elements.

BOOTS Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

CLOTHING Wear long sleeves and long pants to protect arms and legs.

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SAFETY

SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to obtain a replacement. Replacement safety labels are provided by POLARIS at no charge.

q Seat Belt / Driver Warning w Shift Caution

e Proper Use Warning rMax Payload Warning

MAXIMUM PAYLOAD WARNING WARNING

RANGER NEVER EXCEED IF TOTAL PAYLOAD EXCEEDS

MID-SIZE 30 mph (49 kph) 750 lbs. (340 kg)

MID-SIZE CREW 35 mph (56 kph) 1000 lbs. (453 kg)

Part number: 7185085.

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SAFETY

SHIFT CAUTION CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

Part Number: 7181060.

SEAT BELT / DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURYor DEATH Be Prepared

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

Drive Responsibly

Avoid loss of control and rollovers. Avoid abrupt maneuvers, sideways sliding, skidding, or fishtailing, and never do donuts.

Slow down before entering a turn. Avoid hard acceleration when turning, even from a stop. Plan for hills, rough terrain, ruts, and other changes in traction and terrain. Avoid paved surfaces.

Avoid side hilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll, reduce your risk to injury:

Keep a firm grip on the steering wheel or handholds and brace yourself. Do not put any part of your body outside of the vehicle for any reason.

Rollovers have caused severe injuries and death, even on flat, open areas.

Part Number: 7186162.

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SAFETY

PROPER USE WARNING WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries:

Do not allow careless or reckless driving. Make sure operators are 16 or older with a valid drivers license. Do not let people drive or ride after using alcohol or drugs. Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

Do not exceed seating capacity: 2 occupants.

Driving on public roads may be hazardous and could be a violation of the law.

Part Number: 7179978.

FUELTRANSPORT WARNING The Fuel Transport Warningq is located in the cargo box.

WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

Part Number: 7186122.

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SAFETY

PASSENGER/TIRE PRESSURE WARNING The Passenger/Tire Pressure Warning is located in the cargo box.

WARNING

Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box.

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

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.

RANGERMID-SIZE MID-SIZE MID-SIZE CREW

LI-ION EV / EV

MAXIMUM CARGO BOX LOAD

500 lbs. (226 kg) 500 lbs. (226 kg) 500 lbs. (226 kg)

TIRE PRESSURE IN PSI (KPa)

FRONT 10 (69) REAR 10 (69)

FRONT 10 (69) REAR 14 (96)

FRONT 20 (138) REAR 20 (138)

MAXIMUMWEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

1000 lbs. (454 kg)

1250 lbs. (547 kg)

1000 lbs. (454 kg)

Read Operation & Maintenance Manual for more detailed loading information.

Part Number: 7185084.

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SAFETY

OPERATOR SAFETY 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.

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

Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

The driver and all passengers must wear helmets, eye protection, gloves, long-sleeve shirts, long pants, over-the-ankle boots and their seat belts at all times.

Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation.

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

To reduce rollover 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 (unless marked for off-road use). Always avoid paved surfaces.

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 the vehicle before each use to make sure it's in safe operating condition.

Always follow the inspection procedures described in this manual. 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. Always follow proper procedures for turning. 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.

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SAFETY

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 apply throttle suddenly. Never 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 traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow 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 skidding 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 stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

Always be sure there are no obstacles or people behind 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 safety labels. Failure to adhere to either may impact vehicle stability, driveline durability, or general vehicle handling.

Never modify this vehicle through improper installation or use of non- POLARIS approved accessories.

Always re-install plastics and heat shields after vehicle is serviced. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

Always place the transmission in PARK before getting out of the vehicle. Always engage the park brake (if equipped) when leaving the vehicle unattended.

Always stop the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a drivers license and proper training, or accidental starting.

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SAFETY

INTERNATIONALVEHICLE SAFETY LABELS GENERAL ALERT (7183794) Read the owners manual. Never allow anyone under 16 years of age to operate this vehicle.

Never use alcohol or drugs before or while driving or riding.

Do not allow operation on public roads (unless designated for off- highway vehicle access).

Wear approved helmet, goggles, and protective clothing.

Always wear seat belts. Always use the cab nets or doors. Never exceed seating capacity. Always follow proper operating procedures.

SHIFTALERT (7183987) To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

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SAFETY

PASSENGER / TIRE PRESSURE WARNING WARNING

Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Read the Owners Manual. Never carry fuel on this vehicle.

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

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.

EV MID-SIZE MID-SIZE CREW

MAXIMUM CARGO BOX LOAD

226 kg (500 lbs.)

TIRE PRESSURE IN KPa (PSI)

F - 70 (10) R - 110 (16)

F - 69 (10) R - 69 (10)

F - 96 (14) R - 96 (14)

MAXIMUMWEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

454 kg (1000 lbs.)

547 kg (1206 lbs.)

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SAFETY

CLUTCH COVER ALERT (7181427) Keep body parts away from belt. Label Location: on the clutch cover.

HITCH CAPACITYALERT (7183975) Read the owners manual. MAXIMUM DRAWBAR PULL: 1700 N ON LEVEL GROUND MAXIMUM VERTICAL LOAD: 1100 N

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SAFETY

SAFETY WARNINGS WARNING

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

provided with your vehicle. See the OPERATION section of the owners manual for proper operating procedures.

OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).

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

USING ALCOHOL OR DRUGS

WARNING Never consume alcohol or drugs before or while

operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment,

reaction time, balance and perception.

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SAFETY

FAILURE TO INSPECT BEFORE OPERATING WARNING

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the Pre- Ride Inspection outlined in the Operation chapter before each use of your vehicle to make sure it's in safe operating condition. Always follow the

inspection and maintenance procedures and schedules described in this owners manual. See the Periodic Maintenance section of the Maintenance

chapter.

PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear and footwear increases the risk of a serious injuries in the event of an accident.

Operator and/or all passengers must always wear an approved helmet that fits properly, gloves, long-sleeve shirt, long pants, over-the-ankle boots, and eye protection (goggles or face shield).

SEAT BELTS WARNING

Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. The

operator and all passengers MUSTwear their seat belt at all times.

CAB DOORS (IF EQUIPPED) Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests. Always keep hands and feet inside the vehicle at all times.

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SAFETY

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

OPERATING WITH A LOAD ON THE VEHICLE The weight of the cargo, operator, and passengers impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.

Do not exceed vehicle weight capacities. The vehicles maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle.

Always follow these guidelines:

UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:

Operator and/or cargo exceeds half the maximum weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

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SAFETY

IMPROPER TIRE MAINTENANCE WARNING

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as

described in the owner's manual and on safety labels.

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

OPERATING ON PUBLIC ROADS WARNING

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

highway use).

OPERATING AT EXCESSIVE SPEEDS CAUTION

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the

visibility and operating conditions and your skills and experience.

JUMPS AND STUNTS CAUTION

Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, donuts, jumps or other driving stunts. Avoid exhibition driving.

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SAFETY

TURNING IMPROPERLY CAUTION

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this

owners manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.

IMPROPER HILL CLIMBING CAUTION

Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill

climbing as described in this owner's manual.

DESCENDING HILLS IMPROPERLY CAUTION

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owners

manual.

CROSSING HILLSIDES CAUTION

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely

necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.

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SAFETY

STALLING WHILE CLIMBING A HILL CAUTION

Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

If you begin rolling downhill:

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

OPERATING IN UNFAMILIAR TERRAIN CAUTION

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.

CAUTION Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause

loss of control or rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

OPERATING IMPROPERLY IN REVERSE CAUTION

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual.

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

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SAFETY

SKIDDING OR SLIDING CAUTION

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

additional caution when operating on slippery surfaces.

CAUTION Skidding or sliding due to loss of traction can cause loss of control or rollover (if

tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual.

OPERATING OVER OBSTACLES CAUTION

Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over

large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

OPERATING THROUGHWATER CAUTION

Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that

exceeds the floor level of the vehicle.

Always follow proper procedures for operating in water as described in this owners manual.

Wet brakes will have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

31

SAFETY

OPERATING ON FROZEN BODIES OF WATER WARNING

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

your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

OPERATING A DAMAGED VEHICLE CAUTION

Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection

devices, brakes, throttle, and steering systems.

POOR VISIBILITY CAUTION

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

burned out headlamps promptly.

32

SAFETY

HOT EXHAUST SYSTEMS WARNING

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust

system. Use caution when traveling through tall grass, especially dry grass and when traveling through muddy conditions. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass,

weeds, brush, other tall ground cover, and muddy conditions. Promptly remove any grass, debris or foreign matter clinging to the vehicle and pay particular

attention to the exhaust system area.

EXPOSURE TO EXHAUST CAUTION

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

Operate this vehicle only outdoors or in well-ventilated areas.

REFUELING Gasoline is highly flammable and explosive under certain conditions.

Always exercise extreme caution whenever handling gasoline. Always turn off the engine when refueling. Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

Do not overfill 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.

33

SAFETY

IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident.

Always follow the instructions in this owners manual for carrying cargo. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.

UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.

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

34

SAFETY

FEATURES AND CONTROLS COMPONENT LOCATIONS

q ROPS Frame u Cargo Box

w Hip Bars i Fuel Cap

e Front Bumper/Brush Guard

r Headlights

t Radiator

y Tailgate

35

FEATURES AND CONTROLS

CONSOLE

q Cup Holder w Instrument Cluster eMODE Button r Gear Selector t AWD Switch

y 12VAuxiliary Outlet u Steering Wheel Adjustment Lever i Ignition/Light Switch o Storage Tray a Storage Compartment

AUXILIARY OUTLET The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash.

36

FEATURES AND CONTROLS

SWITCHES IGNITION SWITCH/LIGHT SWITCH The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

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

Lights On Lights are on. Electrical circuits are on. Electrical equipment can be used.

Lights Off Lights are off. Electrical circuits are on. Electrical equipment can be used.

Start Turn the key to the START position to engage the electric starter. Turn the key to the LIGHTS ON position after starting the engine.

AWD/DIFFERENTIAL LOCK SWITCH The AWD/Differential Lock Switch has three positions: All Wheel Drive (AWD) Differential Lock/Two Wheel Drive (2WD) Differential Unlock (1WD/Turf Mode)

37

FEATURES AND CONTROLS

AWD/ADC DRIVE MODE SWITCH The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge. Drive mode options include: All Wheel Drive (AWD/4X4) ADC All Wheel Drive (ADC 4X4) TURF Mode (1WD) Two Wheel Drive (2WD/2X4)

STANDARD TURF SWITCH (IF EQUIPPED) The standard Turf switch has two positions: Differential Unlock (1WD/Turf Mode) Differential Lock/Two Wheel Drive (2WD)

38

FEATURES AND CONTROLS

GEAR SELECTOR

To change gears, stop the vehicle, and with the engine idling, move the selector q to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

TIP Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems.

NOTICE

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.

39

FEATURES AND CONTROLS

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

Always shift into low gear for any of the following conditions.

Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads

STEERING WHEEL

The steering wheel can be tilted upward or downward for rider preference.

1. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward.

2. Release the leverq when the steering wheel is at the desired position.

3. Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls.

40

FEATURES AND CONTROLS

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

FOOT PEDALS

BRAKE PEDAL Depress the brake pedalq to slow or stop the vehicle. Apply the brakes while starting the engine.

When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.

41

FEATURES AND CONTROLS

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

This vehicle is equipped with an automatic throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle pedal, engine speed will be limited, and power to the rear wheels will be reduced.

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

TIP This feature will not operate properly if the park brake connector or switch

(under the hood) malfunctions or becomes disconnected, or if the switch has moved. Check for disconnection, then see your dealer or other qualified

service person promptly if this feature fails to operate properly.

1. To set the park brake, apply the brakes.

2. Pull the park brake lever upward as far as possible.

3. To release the park brake, apply the brakes. Press the park brake release inward and move the lever downward as far as possible.

SEAT 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.

42

FEATURES AND CONTROLS

SEAT BELTS

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

The center of the seat is NOTequipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.

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 vehicle.

To wear the seat belt properly, follow this procedure:

1. For 3-point belts, pull the seat belt latchq downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plateq into the bucklew until it clicks.

3. Release the strap, and pull to tighten.

4. To release the seat belt, press the square red button in the buckles center.

43

FEATURES AND CONTROLS

SEAT BELT INSPECTION Inspect all 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 release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.

FUEL CAP The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

CAB NETS (IF EQUIPPED) WARNING

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or

rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle

Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Your POLARIS dealer or qualified technician can assist.

SECURING THE NET 1. Connect the latch at the top edge of the net to the receiver latch mounted on

the front frame.

44

FEATURES AND CONTROLS

OPENING THE NET 1. To exit the vehicle, release the top front latch.

2. Rotate the net rearward and slide the lower net rod out of the mount to remove it.

3. Allow the net to hang freely outside the vehicle while dismounting.

ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING Vehicle rollover could cause severe injury or death. Always avoid operating in

a manner that could result in vehicle rollover.

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.

EXTREME USE 30 AH BATTERY (NON-EPS MODELS ONLY) If your factory-installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, you may need to purchase a 30 AH battery and a battery strap bracket. Your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. See page 92 for the part numbers of POLARIS products.

1. Fully charge the new battery before installing it.

2. To install the 30 AH battery, remove the existing battery.

3. Remove the plastic spacer at the bottom of the battery compartment. Save the spacer for future use.

4. Install the new battery.

45

FEATURES AND CONTROLS

INSTRUMENT CLUSTER

q Speedometer

w Indicator Lamps

eMode Button

r Rider Information Center

46

FEATURES AND CONTROLS

INDICATOR LAMPS LAMP INDICATES CONDITION

Vehicle Speed When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Over Temperature (Coolant)

This lamp illuminates when the engine has reached 232 F (111 C). If the indicator begins to flash, the engine has reached 236 F (113 C); the system will automatically reduce engine power. When the engine reaches 246 F (118 C), the engine will automatically shut off.

Electronic Power Steering (EPS) Warning (if equipped)

This indicator illuminates briefly when the key is turned to the ON position. If light remains on, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

High Beam (if equipped)

This lamp illuminates when the head lamp switch is set to high beam.

Helmet/Seat Belt

This lamp illuminates to alert operator to check all riders seat belts are securely fastened before operating. The drivers seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured. ALWAYS check to ensure all riders are wearing proper safety gear.

Check Engine This indicator appears if an Electronic Fuel Injection (EFI) related fault occurs. DO NOToperate the vehicle if this warning appears or serious engine damage could result. Your dealer can assist.

47

FEATURES AND CONTROLS

RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, your dealer can provide proper diagnosis.

The information center is set to display standard units of measurement and a 12- hour clock at the factory.

q Gear Indicator

This indicator displays gear shifter position.

w Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

e Information Display Area

This area displays the following mode options in this order: odometer, trip meter, tachometer, engine temperature, engine hour meter, service hour interval, and error codes. Cycle through these modes using the mode button. When the vehicle is restarted, this area will display the last mode you were using, rather than starting over at the odometer.

r Battery Under / Over Voltage

This warning indicates the vehicle is operating at an RPM too low to keep the battery charged or if the engine is at idle and a high electrical load (lights, cooling fan, accessories) is applied.

48

FEATURES AND CONTROLS

Lo [VOLTAGE] Battery voltage is too low (below 11V). Drive at a higher RPM or recharge the battery to clear the warning. Ov [VOLTAGE] High electrical load has been applied to the battery (above 15V) or there is a possible issue with another vehicle component. Contact your dealer for assistance.

t Clock The clock displays time in a 12-hour or 24-hour format.

y Service Indicator

A flashing wrench symbol alerts the operator that the preset service interval has been reached. Refer to the Periodic Maintenance Chart section to view what service needs to be carried out at your current service interval.

u 4x4 Indicator This indicator illuminates when the vehicle is in gear and AWD is engaged (switch is on 4x4, AWD or ADC 4x4). There is no indicator for the 2WD setting.

i Turf Mode Indicator (if equipped)

This indicator illuminates when the operator unlocks the differential. Refer to the All Wheel Drive/Rear Differential System section for more info on unlocking the differential.

49

FEATURES AND CONTROLS

MODE BUTTON The button located on the face of the instrument cluster is used to toggle through available mode options in the following order:

Odometer Trip Meter Tachometer Hour Meter Service Interval Diagnostic Display Mode Engine Error Codes (if activated)

When the vehicle is restarted, the rider information center will still be displaying the last mode you were using, rather than starting over at the odometer.

DISPLAY UNITS The instrument cluster can be customized to display either standard or metric units of measurement.

TIP To exit set-up mode at any time, wait 10 seconds. The display automatically

exits and returns to the odometer display.

MEASUREMENT STANDARD METRIC

Distance Miles Kilometers

Fuel U.S. Gallons Liters, Imperial Gallons

Temperature Fahrenheit Celsius

Time 12-Hour Clock 24-Hour Clock

To change display units, do the following:

1. Turn key to OFF position.

2. PRESS and HOLD the Mode Button while turning key to the ON position.

3. The display will flash to the distance setting (mi / km), tap the Mode Button to toggle between units.

4. PRESS and HOLD the Mode Button to save the setting and advance to the next unit option.

5. Repeat procedure to change the subsequent unit settings.

50

FEATURES AND CONTROLS

CLOCK MODE TIP

The clock must be reset any time the battery has been disconnected or discharged.

To set the clock time, do the following:

1. Turn key to the ON position. Use the Mode Button to toggle to the odometer display.

2. PRESS and HOLD the Mode Button until hour segment flashes. Release button.

3. With segment flashing, tap the Mode Button to advance to the desired hour.

4. PRESS and HOLD the Mode Button until the next segment flashes. Release button.

5. Repeat steps 3 and 4 twice to set the 10-minute and 1-minute segments.

6. PRESS and HOLD the Mode Button exit clock mode.

7. Turn key to the OFF position.

ODOMETER The odometer records and displays the distance traveled by the vehicle.

TRIP METER The trip meter records the distance traveled by the vehicle between resets.

To reset the trip meter, PRESS and HOLD the Mode Button until the meter changes to zero.

NOTICE In the Rider Information Center, the trip meter display extends to the tenth

decimal place, but the odometer does not contain decimals.

ENGINE HOURS This screen displays total logged hours of engine operation. Hourglass icon is displayed to indicate this mode is active.

51

FEATURES AND CONTROLS

TACHOMETER The vehicles engine revolutions per minute (RPM) is displayed digitally in the Rider Information Center of the instrument cluster.

TIP Small day-to-day fluctuations in RPM may be normal due to changes in

humidity, temperature, and elevation.

PROGRAMMABLE SERVICE INTERVAL When the number of logged engine operation hours reaches a programmed service interval, the Wrench icon will appear and flash for 5 seconds each time the engine is started. This feature provides a convenient reminder to perform routine maintenance on your vehicle.

NOTICE The service interval is pre-programmed to 50 engine hours at the factory.

To customize the service interval, do the following:

1. From the Service Interval screen, press the Mode Button until remaining service hours display.

2. PRESS and HOLD the Mode Button.

3. When service hours flash, press and RELEASE the Mode Button to set hours to desired setting. PRESS and HOLD the Mode Button to save the new service hour interval.

4. To disable the service interval feature, toggle through the hours setting until OFF appears. PRESS and HOLD the Mode Button to save setting.

DIAGNOSTIC DISPLAY MODE The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer or other qualified technician can provide all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator is activated after the key is turned on. Leave key ON to view the active code (failure code).

Diagnostic mode becomes inaccessible once the warning has been resolved and key is turned OFF. This allows the determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

52

FEATURES AND CONTROLS

ENGINE ERROR CODES The error code screen displays only if the CHECK ENGINE indicator lamp has been activated.

IMPORTANT Error codes are not stored in the systems computer. When the key is turned OFF, the code and message will be lost. If the fault reoccurs, the error will

display again after restarting the engine.

If the CHECK ENGINE lamp illuminates, write down the error code(s) from the display and seek assistance from your dealer or other qualified technician.

If the CHECK ENGINE lamp illuminates but an error code is not displayed, do the following:

1. Toggle the Mode Button through each display screen until appears.

2. PRESS and HOLD the Mode Button to enter the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the Mode Button to advance to the next error code.

5. PRESS and HOLD the Mode Button to exit the diagnostics menu.

Your authorized POLARIS dealer can provide code details and diagnosis.

53

FEATURES AND CONTROLS

54

OPERATION IMPORTANT INFORMATION

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

manual.

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

NOTICE

Excessive heat build-up during the first 3 hours of operation will damage close- fitted engine parts and drive components. Do not operate at full throttle or high

speeds during the first 3 hours of use.

ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever

handling gasoline.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the safe operating range.

3. Complete the New Operator Driving Procedures.

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Pull only light loads.

7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.

8. During the break-in period, change both the oil and the filter at 25 hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.

55

OPERATION

BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt.

PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

ITEM REMARKS PAGE

Brake system/pedal travel Ensure proper operation page 41 page 115

Brake fluid Ensure proper level page 115

Front suspension Inspect, lubricate if necessary page 93

Rear suspension Inspect, lubricate if necessary page 93

Steering Ensure free operation -

Tires Inspect condition and pressure page 119

Wheels/fasteners Inspect, ensure fastener tightness page 119

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels page 94

Coolant level Ensure proper level page 104

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation page 42

Indicator lights/switches Ensure proper operation page 37 page 47

Intake pre-filters Inspect, clean -

Headlamps Check operation, apply POLARIS dielectric grease when lamp is replaced

page 122

56

OPERATION

ITEM REMARKS PAGE

Brake light/tail lamps Check operation -

Seat Latch Push down on the seat back to ensure the latch is secure

-

Seat Belt Check length of belt for damage, check latches for proper operation

page 43

Cab Doors (If equipped) Check doors and latches for wear or damage. -

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

-

SAFE OPERATION PRACTICES 1. Visit the Recreational Off-Highway Vehicle Association web site and take

the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751.

2. Do not allow anyone under 16 years of age or without a valid drivers license to operate this vehicle.

3. Never carry a passenger on this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

5. Never operate with accessories not approved by POLARIS for use on this vehicle.

6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for on-road use).

7. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

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

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

10.Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

11. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

57

OPERATION

12.Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

13.Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

14.Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

KNOW YOUR RIDING AREA/TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

TRAIL ETIQUETTE Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

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

STARTING THE ENGINE 1. Position the vehicle on a level surface outdoors or in a well ventilated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab doors (if equipped).

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the engine.

5. 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.

58

OPERATION

6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts.

7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.

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

STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the key to the OFF position.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

WARNING A rolling vehicle can cause serious injury. Always place the transmission in

PARK before stopping the engine.

BRAKING 1. Release the throttle pedal completely.

NOTICE When the throttle pedal is released completely and engine speed slows to near

idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

PARKING THE VEHICLE 1. Stop the vehicle on a level surface. 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.

2. Place the transmission in PARK.

59

OPERATION

3. Turn the engine off.

4. Engage the parking brake (if equipped).

5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. Remove the ignition key to prevent unauthorized use.

DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction

labels before operating this vehicle.

2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.

3. Perform the pre-ride inspection.

4. Do not tow or carry cargo during this period.

5. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

6. The driver must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times.

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

8. Always make sure all cab doors are closed and latched when riding in this vehicle.

9. Place the transmission in PARK.

10.Start the engine.

11. Apply the brakes and shift into low gear.

12.Check your surroundings and determine your path of travel.

13.Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving.

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OPERATION

14.Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

WARNING Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches

the ground again.

15. Increase speed only after mastering all maneuvers at a slow speed.

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

DO NOT do power slides, donuts, jumps or other driving stunts.

DRIVING WITH A PASSENGER Perform the pre-ride inspection. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

Make sure all passengers are wearing helmets, eye protection, gloves, long- sleeve shirt, long pants and over-the-ankle boots.

Make sure all cab nets or doors (if equipped) are properly secured. Do not carry more than the recommended number of passengers for your vehicle.

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

Vehicle handling may change with a passenger and/or cargo on board. Allow more time and distance for braking.

Always follow all operating guidelines as outlined on safety labels and in this manual.

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OPERATION

DRIVING ON SLIPPERY SURFACES WARNING

Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose

gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

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

Do not operate on excessively rough, slippery or loose terrain. Slow down before entering slippery areas. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

Engage all-wheel drive before wheels begin to lose traction.

NOTICE 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.

Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles:

Always check for obstacles before operating in a new area. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

Move the drive mode switch to low mode if needed. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

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OPERATION

DRIVING UPHILL Whenever traveling uphill, follow these precautions:

Avoid excessively steep hills. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

Always travel straight uphill. Keep both feet on the floor. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

Proceed at a steady rate of speed and throttle opening. 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.

DRIVING DOWNHILL When driving downhill, follow these precautions:

Avoid excessively steep hills. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

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

Slow down. Apply the brakes slightly to aid in slowing.

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

If crossing a sidehill is unavoidable, follow these precautions:

Slow down. Exercise extreme caution. Avoid crossing the side of a steep hill. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

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OPERATION

DRIVING THROUGHWATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards.

NOTICE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can

provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 114, and take the vehicle in for

service at the first opportunity.

Follow these procedures when operating through water:

Determine water depths and current before entering water. Choose a crossing where both banks have gradual inclines. Proceed slowly, avoiding rocks and obstacles. Avoid operating through deep or fast-flowing water.

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

death. Never cross deep or fast-flowing water with your vehicle

After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

NOTICE After running your vehicle in water, it's critical that you perform the services

outlined in the Periodic Maintenance Chart. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

DRIVING IN REVERSE Follow these precautions when operating in reverse:

Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing.

Always avoid backing downhill. Back slowly. Apply the brakes lightly for stopping. Avoid turning at sharp angles. Never open the throttle suddenly.

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OPERATION

PARKING THE VEHICLE To park the vehicle, do the following:

1. Apply the brakes. Stop the vehicle on a level surface.

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

3. Place the transmission in PARK.

4. Turn the engine off.

5. Engage the park brake (if equipped).

6. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

7. Remove the ignition switch key to prevent unauthorized use.

PARKING ON AN INCLINE Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Engage the parking brake (if equipped).

4. Turn the engine off.

5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. Block the rear wheels on the downhill side.

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OPERATION

HAULING CARGO WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always

follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUMWEIGHT CAPACITYof the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the

trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

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 SAFELYARRANGED 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

vehicle rollover. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 MPH (16 km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing

loads in rough terrain, while cornering, or while ascending or descending a hill. If the vehicle is capable, never exceed 43 MPH (70 km/h) if total payload

exceeds 335 lbs. (152 kg). Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo

box.

Your vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo.

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OPERATION

Loads should be centered on the vehicle and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle.

MAXIMUM CARGO CAPACITY 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.

MODEL MAXIMUM CAPACITIES (LEVEL

GROUND)

CARGO BOX

RANGER 500 1000 lbs. (454 kg) 500 lbs. (227 kg)

BELT LIFE To extend belt life, use low gear when hauling or towing heavy cargo.

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OPERATION

TOWING LOADS WARNING

Towing improperly can alter vehicle handling and may cause loss of control or brake instability.

Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. When towing a disabled vehicle, place the disabled vehicles transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

3. Towing a trailer increases braking distance. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

4. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

5. Do not tow more than the recommended weight for the vehicle.

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

7. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

TOTAL TOWED LOAD WEIGHT (LEVEL

GROUND)

TOTAL TOWED LOAD WEIGHT (15

GRADE)

TOTAL HITCH

VERTICAL WEIGHT (TONGUE WEIGHT)

MAXIMUM TOWING SPEED

MAXIMUM TOWING SPEED (ROUGH GROUND, CORNER-

ING, ASCEND- ING /

DESCEND- ING)

1500 lbs. (681 kg)

850 lbs. (386 kg)

150 lbs. (68.1 kg)

10 MPH (16 km/h)

5 MPH (8 km/h)

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OPERATION

DUMPING THE CARGO BOX To dump the cargo box, do the following:

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. Apply the brakes.

3. Set the gear selector to PARK.

4. Turn the key to the off position.

5. Dismount vehicle.

6. Ensure that the cargo is positioned evenly or toward the front of the cargo box.

7. Release the tailgate latches.

WARNING Never operate the dump lever without ensuring that the load is positioned

evenly or at the front of the box. 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.

8. Stand clear and pull up on the cargo box release lever.

9. Lift the front of the cargo box to dump the cargo.

10.Lower the cargo box and push down securely to latch.

11. Close the tailgate and secure the latches.

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

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

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OPERATION

ALLWHEEL DRIVE (AWD) SYSTEM The standard All Wheel Drive system is controlled by the AWD switch. When the switch is in the 2X4 positionw, the vehicle is in two-wheel drive at all times. When the switch is in the AWD position q, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.

q All-Wheel Drive (AWD)

w Two-Wheel Drive (2WD)

ENGAGING/DISENGAGING AWD The AWD switch may be turned on or off while the vehicle is moving.

Press the top of the rocker switch to engage AWD. Press the bottom of the switch to operate in two wheel drive.

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 demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

NOTICE Switching to AWD while the rear wheels are spinning or slipping may cause

severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

ALLWHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential.

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OPERATION

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

q All-Wheel Drive (AWD) w Differential Lock e Differential Unlock

Engage the AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage. Always switch to AWD while the rear wheels have

traction or are at rest.

DISENGAGING AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction.

In some situations, the front gearcase may remain locked after turning the AWD switch off. If this occurs, you may notice increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gearcase.

To disengage AWD, do the following:

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet (3 m).

3. Stop completely.

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OPERATION

4. Shift into low gear and drive forward.

5. If the front gearcase remains locked after following these instructions, see your dealer or other qualified service person for service.

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

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

WARNING Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches

the ground again.

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

NOTICE 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.

WARNING Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or

descending a hill.

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OPERATION

ALLWHEEL DRIVE/ACTIVE DESCENT CONTROL SYSTEM ADC models are equipped with a drive mode switch that controls the AWD system. The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge.

DRIVE MODE OPERATION Use the drive mode switch to engage AWD (4X4), ADC 4X4, TURF mode or 2X4. The vehicle automatically engages 4X4 when operating in reverse if the drive mode is set to either AWD (4X4) or ADC 4X4.

Always operate in low gear and engage ADC 4X4 when transporting heavy loads and/or when towing.

Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

WARNING Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO NOToperate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain

such as sand, gravel, ice, snow, obstacles, and water crossings.

DRIVE MODE SWITCH Press and release the top of the switch q to toggle through the drive mode options, which display in the information center of the gauge for several seconds.Press and release the bottom of the switchw to toggle to a previous option. When the switch is released, the drive mode displayed in the information center is the active drive mode.

NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4

while the rear wheels have traction or are at rest.

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OPERATION

DRIVE MODE INDICATOR The Drive Mode Indicator displays the active drive mode. The Drive Mode Indicator will match the information displayed in the Rider Information Center. An amber light flashes when drive mode selection is pending. Once in the selected drive mode, a solid amber light will show next to the active drive mode.

ACTIVE DESCENT CONTROL (ADC) SYSTEM (IF EQUIPPED) The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

Always operate in low gear and engage ADC 4X4 when transporting heavy loads and/or when towing.

Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

ENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically engage when both of the following conditions occur:

The drive mode must be in the ADC 4X4 position. The transmission must be in gear (high, low or reverse).

DISENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically disengage if at least one of the following conditions occur:

The drive mode is changed from the ADC 4X4 position. The transmission is shifted to neutral or park.

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OPERATION

WINCH GUIDE WINCH SAFETY These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.

WARNING Improper winch use can result in SEVERE INJURYor DEATH. Always follow

all winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term winch cable will be used for either unless noted otherwise.

WINCH SAFETY PRECAUTIONS 1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to jerk a load attached to the winch with a moving vehicle. See the Shock Loading section on page 84.

7. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

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

10.Always apply your vehicles park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicles centerline whenever possible.

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WINCH GUIDE

12. If winching at an angle is unavoidable, follow these precautions:

a. Look at the winch drum occasionally. Never let the winch cable stack or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation.

13.Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14.Never attempt to winch loads that weigh more than the winchs rated capacity.

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

16.Never touch, push, pull or straddle the winch cable while winching a load.

17.Never let the winch cable run through your hands, even if wearing heavy gloves.

18.Never release the clutch on the winch when the winch cable is under load.

19.Never use the winch for lifting or transporting people.

20.Never use the winch to hoist or suspend a vertical load.

21.Always inspect your winch and winch cable before each use.

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WINCH GUIDE

22.Never winch the hook fully into the winch. This can cause damage to winch components.

23.Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.

24.Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

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WINCH GUIDE

WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch.

TIP Consider practicing the operation and use of your winch before you actually

need to use it in the field.

WARNING

Improper winch use can result in SEVERE INJURYor DEATH. Always follow all winch instructions and warnings in this manual.

Each winching situation is unique.

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

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicles park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

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WINCH GUIDE

4. Always use the hook strap when handling the hook.

WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY.

Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.

TIP A tow strap is NOT intended to stretch. A recovery strap is designed to

stretch.

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WINCH GUIDE

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

or DEATH. See the Shock Loading section on page 84.

Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURYor DEATH in the event of failure. For your safety, always replace

POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other

qualified dealer.

If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.

If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to Tread Lightly (treadlightly.org).

Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.

Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winchs pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

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WINCH GUIDE

8. Read and adhere to the following information for winch damping to ensure safe winch use.

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

b. Lay the damper on top of the mid-point of the winch cable length that is spooled out.

c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.

d. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10.Never use straps, chains or other rigging items that are damaged or worn.

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 84. For your safety, always follow these guidelines when winching a vehicle free:

a. Release the winch clutch and spool out the necessary length of winch cable.

b. Align the winch cable as close as possible to the winching vehicles centerline.

c. Attach the winch cable hook to the anchor point or the stuck vehicles frame following instructions in this manual.

d. Re-engage the clutch on the winch.

e. Slowly winch in the slack in the winch cable.

f. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.

g. Shift to the lowest gear available on the stuck vehicle.

h. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.

i. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch.

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WINCH GUIDE

j. Detach the winch cable hook.

k. Rewind the winch cable evenly back onto the winch drum following the instructions in this manual.

12.Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.

13.Extensive winching will run down the battery on the winching vehicle. Let the winching vehicles engine run while operating the winch to prevent the battery from running low if winching for long periods.

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

15.After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task.

a. Release the clutch on the winch.

b. Feed out the winch cable that is unevenly bunched up in one area.

c. Re-engage the winch clutch.

d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the hook strap.

e. Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum.

f. Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable.

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WINCH GUIDE

WINCH CABLE CARE WARNING

Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.

For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being straightened out, this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

A kinked winch cable made of wire rope that has been straightened out is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.

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

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WINCH GUIDE

SHOCK LOADING WARNING

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

Winch cables are designed to NOTabsorb energy. This is true of both wire-rope and synthetic-rope winch cables.

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

WARNING SEVERE INJURYor DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (jogging). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic bungie cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

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WINCH GUIDE

WINCH MAINTENANCE AND SERVICE SAFETY WARNING

Improper or lack of winch maintenance and service could lead to SEVERE INJURYor DEATH. Always follow all winch instructions and warnings in this

manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.

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

WARNING Failure of a stretched rope under winching conditions will release all of the

stored energy. This will increase the chances of SEVERE INJURYor DEATH.

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WINCH GUIDE

86

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 vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

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 Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the inside of the lower left frame tube (below drivers foot area).

ELECTROMAGNETIC INTERFERENCE This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of UN ECE Regulation 10.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

87

EMISSION CONTROL SYSTEMS

88

MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicles emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owners manual.

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer, or other qualified person. Equivalent parts may be used for emissions-related service.

Service and adjustments are important for proper vehicle operation. If youre not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

SEVERE USE DEFINITION Frequent immersion in mud, water or sand Frequent or prolonged operation in dusty environments Short trip cold weather operation Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.

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MAINTENANCE

MAINTENANCE CHART KEY SYMBOL DESCRIPTION

XU Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized dealer or other qualified person perform these services.

E Emission Control System Service (California)

WARNING Improperly performing the procedures marked with a D could result in

component failure and lead to serious injury or death. Have an authorized dealer or other qualified person perform these services.

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

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HRS CLNDR MILES

(KM)

Steering - Pre-Ride -

Make adjustments as needed.

Front-suspension - Pre-Ride -

Rear-suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake pedal travel - Pre-Ride -

Brake systems - Pre-Ride -

Wheels /fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine Oil Level - Pre-Ride -

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

as needed

Coolant - Daily - Check level

Head lamp / tail lamp / worklight - Daily -

Check operation; apply dielectric grease to electrical connections if replacing lamps

XU E Air filter - Weekly - Inspect; replace as needed

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MAINTENANCE

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HRS CLNDR MILES

(KM)

XU D Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

Fuel System 25 H Monthly - Inspect; Cycle the Key to pressurize the fuel pump; check lines and fittings for leaks and abrasion.

XU Front Gearcase oil 25 H Monthly - Perform a break-in oil level check

XU Transmission fluid 25 H Monthly - Perform a break-in oil level check

XU Engine oil change (break-in) 25 H Monthly - Perform a break-in oil

change at one month

XU General lubrication 50 H 3 M - Lubricate all grease fittings, pivots, cables, etc.

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

D Steering 50 H 6 M - Lubricate

XU Front Suspension 50 H 6 M - Lubricate

XU Rear Suspension 50 H 6 M - Lubricate

D E Throttle Pedal 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

E Air intake ducts/ flange 50 H 6 M 500 (800) Inspect ducts for proper

sealing/air leaks

Drive belt 50 H 6 M 500 (800)

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

XU Shock absorbers 50 H - 500 (800) Inspect for leaks, loose joints, and wear

XU Engine oil and filter change 100 H 6 M 1000

(1600) Change oil and filter; (perform a break-in oil change at one month)

XU Oil lines and fasteners 100 H 6 M - Inspect for leaks and loose

fittings

XU Front Gearcase oil 100 H 6 M - Inspect level; change yearly

XU Transmission fluid 100 H 6 M 1000 (1600) Change fluid

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MAINTENANCE

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HRS CLNDR MILES

(KM)

D E Fuel System 100 H 12 M 1000

(1600)

Cycle the key to prime and pressurize the fuel system. Check for leaks at fuel cap, fuel line / rail, and fuel pump; Replace lines every 2 years

XU Radiator 100 H 12 M - Inspect; clean external surfaces

XU Cooling Hoses 100 H 12 M - Inspect for leaks; clean external surfaces

XU Engine mounts 100 H 12 M - Inspect

Exhaust muffler /pipe 100 H 12 M - Inspect

D E Spark plug 100 H 12 M 1000

(1600) inspect; replace as needed

XU Wiring 100 H 12 M -

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

D Clutches 100 H 12 M 1000 (1600)

Inspect; clean; replace worn parts

D Front wheel bearings 100 H 12 M - Inspect; replace as needed

D Brake fluid 200 H 24 M - Change every two years

XU D Shock absorbers 250 H - 2500

(4000) Replace or rebuild (if applicable)

Spark arrestor - 60 M - Clean out

D E Valve clearance 500 H - 5000

(8000) Inspect; adjust

D Toe adjustment - Inspect periodically; adjust when parts are replaced

Headlight aim - Adjust as needed

XU = Perform these procedures more often for vehicles subjected to severe use. E= Emission Control System Service (California) D = Have an authorized dealer perform these services.

*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.

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MAINTENANCE

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

ITEM LUBE METHOD

Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick. See page 94.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 115.

Transmission Oil (Main Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

See page 98.

Demand Drive Fluid (Front Gearcase)

Demand Drive Fluid See page 100.

Prop Shaft U-Joint Grease Locate fittings and grease.

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MAINTENANCE

ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil.

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.

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.

OIL RECOMMENDATIONS POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities.

Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See the Polaris Products section for part numbers.

NOTICE

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

94

MAINTENANCE

OIL CHECK WARNING

Continuous contact with used motor oil has caused skin cancer in laboratory animal tests. Avoid prolonged contact. Wash skin with soap and water.

Launder or discard soiled clothing.

The oil dipstick and fill tube is located on the engine. Access the dipstick through the right rear wheel well.

To check the oil, do the following:

1. Position the vehicle on a level surface and turn the engine off.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the dipstick areaq before unscrewing the dipstick. Unscrew the dipstick. Wipe it dry with a clean cloth.

4. Reinstall and tighten the dipstick.

5. Unscrew the dipstick and check the oil level.

6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULLw and ADDemarks. Do not overfill.

7. Reinstall and tighten the dipstick.

95

MAINTENANCE

OIL AND FILTER CHANGE

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart.

The engine drain plugw is located on the bottom of the crankcase. To change the oil and filterq, do the following:

1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes.

2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

3. Clean the area around the drain plug.

IMPORTANT The sealing surfaces on drain plug and crankcase should be clean and free of

burrs, nicks or scratches.

4. Place a drain pan beneath engine crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

7. Reinstall the drain plug. Torque to 12 ft. lbs. (16 Nm).

8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it.

9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter O-ring is completely removed.

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MAINTENANCE

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

11. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 3/4 turn.

12.Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick (or the oil fill cap on the top of the engine) and fill the sump with two quarts (1.9 L) of recommended oil.

13.Reinstall and tighten the dipstick (and the oil fill cap, if applicable).

14.Make sure the transmission is in PARK. Apply the brakes.

15.Start the engine. Allow it to idle for one to two minutes.

16.Stop the engine. Inspect for leaks.

17.Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

18.Dispose of used filter and oil properly.

WARNING Continuous contact with used motor oil has caused skin cancer in laboratory

animal tests. Avoid prolonged contact. Wash skin with soap and water. Launder or discard soiled clothing.

97

MAINTENANCE

GEARCASES TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole.

TORQUE

Transmission Drain / Fill Plug: 14 ft-lbs (19 Nm)

OIL CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

To check the transmission fluid, do the following:

1. Position the vehicle on a level surface and turn off the engine.

2. Remove the fill plugq.

3. Check the fluid level.

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

5. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

FLUID CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate.

1. Insure the engine is off and remove the fill plugq.

2. Place a drain pan under the drain plugw.

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

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

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

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MAINTENANCE

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

ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:

Operation in ADC mode for prolonged periods. Constant ADC operation on hilly or mountainous terrain. ADC is the primary mode of all-wheel-drive operation.

TIP If the front gearcase makes excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your dealer or other

qualified service person for service.

OIL CHECK The front gearcase fill plugq is located on the right side of the front gearcase.

1. Position the vehicle on a level surface.

2. Remove the fill plugq. Check the oil level.

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

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 plugw on the bottom right-hand side.

5. Remove the drain plug. Drain the oil.

6. Clean and reinstall the drain plug. Torque to specification.

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

8. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

9. Check for leaks.

10.Discard used oil properly.

GEARCASE SPECIFICATION CHART

GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE

DRAIN PLUG/ LEVEL CHECK PLUG TORQUE

Transmission (Main Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

41 oz. (1200 ml)

10-14 ft. lbs. (14-19 Nm)

10-14 ft. lbs. (14-19 Nm)

Demand Drive Unit (Front Gearcase)

Demand Drive Fluid

9.3 oz. (275 ml)

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

11 ft. lbs. (15 Nm)

101

MAINTENANCE

SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

NOTICE

Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent.

SPARK PLUG GAP/TORQUE MODEL ELECTRODE GAP NEW OR USED PLUG

TORQUE

RANGER 500 .03-.04 (.7.9 mm) 14.8 ft. lbs (20 Nm)

RANGER 570 .03-.04 (.7.9 mm) 9 ft. lbs. (12 Nm)

SPARK PLUG INSPECTION 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.

CAUTION A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

To inspect the spark plugs, do the following:

1. Lift the cargo box to access the spark plugs.

2. Remove the spark plug cap. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

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MAINTENANCE

NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

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 or poor fuel quality.

103

MAINTENANCE

COOLING SYSTEM The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator.

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

ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water.

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

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

NOTICE 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.

104

MAINTENANCE

RADIATOR COOLANT LEVEL

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

TIP This procedure is required only if the cooling system has been drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in

the radiator should also be inspected.

1. Lift the hood.

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

pressure cap.

2. Slowly remove the radiator capq.

3. View the coolant level through the opening.

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MAINTENANCE

4. Use a funnel and slowly add coolant as needed.

5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.

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

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottlew.

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

TIP If coolant must be added often, or if the overflow bottle runs completely dry,

there may be a leak in the system. Your dealer can inspect the cooling system.

106

MAINTENANCE

POLARIS VARIABLE TRANSMISSION (PVT) SYSTEM

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVTsystem. 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 PVTsystem rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for

your own safety and the safety of others:

Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

See your dealer or other qualified service person as outlined in the owner's manual.

This PVTsystem 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.

107

MAINTENANCE

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

WARNING Failure to remove ALL debris when replacing the belt could result in vehicle

damage, loss of control and severe injury or death.

To replace the belt, do the following:

1. Position the vehicle on a level surface. Block the wheels to prevent vehicle movement. Place the transmission in neutral.

2. Lift the cargo box.

3. Remove the clutch coverq using a 3/8 socket with ratcheting wrench and extension.

4. Pull the bottom of the cover outward and over the suspension to remove it.

5. Make sure the cover gasket does not fall out of the groove when removing the cover.

6. Squeeze the beltw together so that it submarines further into the driven clutch, creating slack in the belt between the clutches.

7. Remove the belt by using the slack to pull part of the belt off the driven clutch.

8. Rotate the driven clutch by hand until the belt is completely off.

9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it.

10.Remove all debris wrapped in and around the PVTsystem.

11. Remove all debris from the entire clutch air duct passage.

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MAINTENANCE

12.Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist.

TIP Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVTcomponents

(belt, cover, etc.).

13.To install a belt, place one end of the belt over the driving clutch. Route the belt over the top of the driven clutch and down into the groove of the clutch to allow slack in the belt. Rotate the driven clutch by hand until the belt falls into place.

14.Reinstall the clutch cover in the reverse order of removal, fitting the top of the cover into place, then working the bottom of the cover over the suspension.

15. Install all clutch cover screws. Torque to 4-5 ft. lbs. (5.5-6.5 Nm).

109

MAINTENANCE

POLARIS VARIABLE TRANSMISSION (PVT) SYSTEM PVT DRYING

There may be some instances when water is ingested into the PVTsystem. Use the following instructions to dry it out before operating:

1. Position the vehicle on a level surface.

2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug.

3. Place the transmission in PARK.

4. Start the engine.

5. 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 five (5) seconds.

6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range.

7. Test for belt slippage. If the belt slips, repeat the process.

8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.

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MAINTENANCE

VEHICLE IMMERSION WARNING

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before

starting the engine. Your POLARIS dealer can provide this service.

If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below:

1. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Remove the spark plugs. Turn the engine over several times using the electric start.

4. Dry the spark plugs and reinstall, or replace with new plugs.

5. Attempt to start the engine. If necessary, repeat the drying procedure.

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

7. If water has been ingested into the PVT follow the procedure for drying.

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FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart.

1. Lift the cargo box.

2. Clean all dirt and debris from the air box area.

3. Unlatch the two (2) cover clips and carefully remove the air box cover. Inspect the seal between the cover and air box to ensure the seal is not torn and has been maintaining a proper seal.

4. Inspect the air filter and air box for dirt, debris, oil or water. If the filter needs to be replaced, remove the worm gear clamp from the filter neck with a flat- blade screwdriver or 6mm socket. Slide the filter rearward to remove it from the boot, then lift it straight upward and out of the air box.

5. With the filter removed, clean the intake boot and air box thoroughly and wipe well with a clean, dry cloth.

NOTICE Dirt or debris in the intake boot could result in severe engine damage. Always

clean all dirt and debris from the intake boot before installing the filter.

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6. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to clean the air filter.

NOTICE Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. See page 92 for the part numbers

of POLARIS products.

7. Make sure the filter is fully seated on the intake boot and that there is no gap between the filter and boot after installation. Tighten the worm gear clamp to 24 in. lbs. (2.7 Nm).

8. Reinstall the air box cover. Make sure both hinges are fully inserted. Secure the cover clips.

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MAINTENANCE

SPARK ARRESTOR WARNING

Never operate the vehicle without the spark arrestor. Remove any combustible materials from the area.

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

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.

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

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

Never go under the vehicle while it is inclined. Wear eye protection and gloves while servicing.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.

1. Remove the arrestor clean-out plugq located on the bottom of the muffler.

2. Place the transmission in PARK.

3. Start the engine.

4. Purge accumulated carbon from the system by momentarily revving the engine several times.

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

6. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Block the wheels.

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7. Repeat steps 4 and 5 until no more particles are expelled when the engine is revved.

8. Stop the engine. Allow the arrestor to cool.

9. Reinstall the arrestor plug and remove the outlet cover or plug.

BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes.

BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING After opening a bottle of brake fluid, always discard any unused portion. Never

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

accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown.

1. Position the vehicle on a level surface and turn off the engine.

2. View the brake fluid level at the reservoir in the drivers side wheel well. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the upper level line, open the hood and 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.

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BRAKE INSPECTION WARNING

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

pad and caliper.

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. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol.

5. Inspect the brake disc spline and pad wear surfaceq for excessive wear. Change pads when worn to 0.030" (0.762 mm).

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MAINTENANCE

SUSPENSION ADJUSTMENT Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension.

Always heed the following rules if you make adjustments to this suspension.

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

Always apply the same adjustment setting to both rear wheels. Never operate the vehicle on the highest (stiffestw) or second highest preload settings without a total combined payload in the vehicle of 450 lbs. (204 kg) or more. Payload includes the driver, approved accessories and cargo. Never exceed the stated load capacity for this vehicle.

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STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart section.

1. Position the vehicle on level ground.

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 authorized dealer.

POWER STEERING UNIT (IF EQUIPPED) If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these arease thoroughly.

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TIRES 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 3 mm (1/8) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS

approved size and type of tires for this vehicle when replacing tires.

AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut.

Lug Nut (Aluminum Wheels)

Front and Rear

30 ft. lbs. (41 Nm) PLUS 1/4 TURN or 90 degrees

2-Piece Flange Nut (Steel Wheels)

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

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

Hub Retaining Nut Rear 110 ft. lbs. (149

Nm)

Front 80 ft. lbs. (108.5 Nm)

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MAINTENANCE

TIRE TREAD DEPTH Always replace tires when tread depth is worn to 3 mm (1/8) or less.

WHEEL REMOVAL 1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the wheel.

WHEEL INSTALLATION WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all

nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your dealer can assist.

1. Place the transmission in PARK.

2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

3. Attach the wheel nuts and washers and finger-tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

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FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.

The fuse box is located in the electrical compartment under the left rearmost seat. Spare fuses are provided in the fuse box.

If you suspect that a fuse or relay may not be working properly, your dealer can assist.

FUSE SIZE FEATURE SUPPORTED

5A Brake Light

10A Drive System, Fuel Pump

20A EFI, Power Steering (if equipped), Lights, Accessories

20A Circuit Breaker Fan

FUSE BOX DIAGRAM

HEAD- LIGHT RELAY

FAN RELAY EFI RELAY

FUEL PUMP RELAY

CHASSIS RELAY

SPARE 5A

SPARE 10A

EPS RELAY (OPT)

FAN 20A CB

EFI 20A

FUEL PUMP 10A

BRAKE LIGHT 5A

SPARE 20A

EPS (OPT) 20A

LIGHTS 20A

DRIVE 10A

ACCY 20A

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LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.

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

HEADLIGHT LAMP REPLACEMENT CAUTION

Hot components can cause burns to skin. Allow lamps to cool before servicing.

To replace the headlight lamp, do the following:

1. Access the headlamp wiring harnesses through the front wheel wells.

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.

TIP Make sure the tab on the lamp locates

properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

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MAINTENANCE

HEADLIGHT BEAM ADJUSTMENT

To adjust the headlight beam, do the following:

1. Place the vehicle on a level surface with the headlight approximately 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. Include the weight of a rider on the seat while performing this step.

5. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

BRAKE LIGHTS When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.

To check the brake lights, do the following:

1. Turn the key 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.

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BATTERY 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.

Your vehicle has a low-maintenance 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.

BATTERY REMOVAL 1. Access the battery via the front underhood storage.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle.

BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions in the AGM Battery Maintenance and Charging section before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Secure the battery hold-down strap.

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.

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MAINTENANCE

AGM BATTERY MAINTENANCE AND CHARGING 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.

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. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation and reduced battery life.

If you do not drive the vehicle for more than TWOWEEKS, Polaris recommends using a BatteryMINDer 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer. During charging, place the charger outside of the vehicle and protect it from moisture.

NOTICE For added convenience Polaris offers the BatteryMINDer Accessory Vehicle

Power Plug (PN 2830518) which allows easy connection to the vehicle's battery through the 12V auxiliary outlet. (See the Auxiliary Outlet section for the location of the 12V auxiliary outlet.) Use a smartphone to view the power plug

accessory via the QR code below.

If you plan to store the vehicle for ONE MONTH or longer, remove the battery from the vehicle, then store the battery in a cool and dry location. Continue to maintain the battery with the BatteryMINDer 2012 AGM - 2 AMP charger.

When using an automatic charger other than a BatteryMINDer 2012-AGM - 2 AMP charger, refer to the charger manufacturer's instructions for recharging.

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If using a constant current charger (instead of BatteryMINDer 2012 AGM - 2 AMP charger), use the guidelines below. Always verify battery condition before and 1-2 hours after the end of charging.

State of Charge Voltage (DC) Action Charge Time* 100% 12.8-13.0 volts None, check

monthly None required

75%-100% 12.6-12.8 volts May need slight charge, if no charge given, check in 2

weeks

3-6 hours

50%-75% 12.3-12.6 volts Needs charge 5-11 hours 25%-50% 12.0-12.3 volts Needs charge At least 13 hours 0%-25% 12.0 volts or less Needs charge At least 20 hours

* Using AGM specific charger at standard amps specified on top of battery

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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.

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

NOTICE Certain products, including insect repellents and chemicals, will damage

plastic surfaces. Do not allow these types of products to contact the vehicle.

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.

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.

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

Wheel bearings Radiator Transmission seals Brakes

Cab and body panels Labels and decals Electrical components and wiring Air intake components

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If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer, or other qualified person, to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.

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.

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

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 polished 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 outlined above.

STORAGE TIPS NOTICE

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.

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CLEAN THE EXTERIOR Make any necessary repairs and clean the vehicle as recommended.

STABILIZE THE FUEL 1. Fill the fuel tank.

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

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

OIL AND FILTER Change the oil and filter. See the Engine Oil section.

AIR FILTER / AIR BOX Replace the air filter. See Maintenance Chapter. Clean the air box.

FLUID LEVELS Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.

Demand drive fluid (front gearcase) Rear gearcase fluid (if equipped) Transmission fluid Brake fluid (change every two years and any time the fluid looks dark or contaminated)

Coolant (test strength/fill)

INSPECTAND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

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FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel

treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 11.5 oz. (29.544 cc.) of engine oil. To access the plug holes, use a section of clear 6 mm (1/4) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall the cap onto the plug at this step.

5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

6. Reinstall the spark plug caps.

7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline.

BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.

STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

REMOVAL FROM STORAGE WARNING

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

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

2. Make sure spark plugs are tight.

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3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection. Tightness of the bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart.

TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle.

1. Apply the brakes.

2. Place the transmission in PARK. Stop the engine.

3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. Engage the park brake.

4. Remove the key to prevent loss during transporting.

5. Secure the fuel cap (if equipped) and seat. Ensure that the seat is attached correctly and is not loose.

WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle.

Secure or remove all cargo, and inspect the unit for loose parts prior to transport. If transporting the vehicle in a non-enclosed trailer, then the vehicle must FACE FORWARD, or roof must be removed. Failure to comply may allow airflow, vibration, or other factors to separate the roof from the vehicle and

cause an accident, resulting in serious personal injury or death.

6. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

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132

SPECIFICATIONS RANGER 500 MaximumWeight Capacity (includes weight of operator, passenger, cargo, accessories)

1000 lbs. (454 kg)

Dry Weight 1080 lbs. (490 kg)

Test GVW - Rollover Protection System (ROPS)

2255 lbs. (1023 kg) per OSHA 29 CFR 1928.53

Fuel Capacity 8.8 gal. (33.3 L)

Engine Oil Capacity 2 qts. (1.9 L) (570)

Coolant Capacity 120 oz. (3.5 L)

Overall Length 110 in. (279.4 cm)

Overall Width 58 in. (147.3 cm)

Overall Height 73 in. (185 cm)

Wheelbase 73 in. (185 cm)

Cargo Box Dimensions (Inside) 32x42x11.5 in. (81x107x29 cm)

Ground Clearance 10 in. (25.4 cm)

Min. Turning Radius 150 in. (381 cm)

Towing Capacity 1500 lbs. (680.4 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load 500 lbs. (227 kg)

Engine Single overhead cam, 2 valve 4 stroke single cylinder.

Displacement 500 cc

Bore x Stroke (mm) 93 mm x 73.6 mm

Alternator Output 560 W@ 3000 RPM

Compression Ratio 10:1

Starting System Electric

Fuel System Electronic Fuel Injection

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SPECIFICATIONS

Ignition Timing ECU Controlled

Spark Plug Autolite 5924 / 0.030 - 0.037 (0.85 +/- 0.08 mm)

Lubrication System Wet Sump

Cooling Liquid

Front Suspension McPherson Strut w/9 in. (22.7 cm) of travel

Rear Suspension Dual A-arm, Anti-Sway Bar w/10 in. (25.4 cm) of travel

Throttle Body Size 40 mm

Ignition System Digital CDI

Driving System Type PVT

Shift Type Single Lever (console)

Gear Reduction - Low 28.84:1

Gear Reduction - Reverse 25.83:1

Gear Reduction - High 9.65:1

Drive Ratio - Front 3.818:1

Tire Size - Front 24 x 8 - 12

Tire Size - Rear 25 x 9 - 12

Tire Pressure - Front 10 psi (69 kPa)

Tire Pressure - Rear 10 psi (69 kPa)

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

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

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

Indicator Light 1.0 W

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SPECIFICATIONS

RANGER 570 MaximumWeight Capacity (includes weight of operator, passenger, cargo, accessories)

1000 lbs. (454 kg)

Dry Weight 1075 lbs. (488 kg) (570) 1100 lbs. (499 kg) (570 EPS)

1140 lbs. (517 kg) (570 w/park brake)

Test GVW - Rollover Protection System (ROPS)

2255 lbs. (1023 kg) per OSHA 29 CFR 1928.53

Fuel Capacity 8.8 gal. (33.3 l)

Engine Oil Capacity 2 qts. (1.9 l) (570)

Coolant Capacity 120 oz. (3.5 l)

Overall Length 110 in. (279.4 cm)

Overall Width 58 in. (147.3 cm)

Overall Height 73 in. (185 cm)

Wheelbase 73 in. (185 cm)

Cargo Box Dimensions (Inside) 32x42x11.5 in. (81x107x29 cm)

Ground Clearance 10 in. (25.4 cm)

Min. Turning Radius 150 in. (381 cm)

Towing Capacity 1500 lbs. (680.4 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load 500 lbs. (227 kg)

Engine Dual overhead cam, 4 valve 4 stroke single cylinder.

Displacement 567 cc (570)

Bore x Stroke (mm) 99mm x 73.6mm (570)

Alternator Output 560 W@ 3000 RPM

Compression Ratio 10:1 (570)

Starting System Electric

Fuel System Electronic Fuel Injection

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SPECIFICATIONS

Ignition Timing ECU Controlled 32 +/- 2 @ 5000 RPM

Spark Plug NGK MR7F / .031 (0.7-0.9 mm)

Lubrication System Wet Sump

Cooling Liquid

Front Suspension McPherson Strut w/8 in. (20.3 cm) of travel (570)

Rear Suspension Independent (23 cm) of travel (570)

Throttle Body Size 42 mm (570)

Ignition System Digital CDI

Driving System Type PVT

Shift Type Single Lever (console)

Gear Reduction - Low 28.84:1

Gear Reduction - Reverse 25.83:1

Gear Reduction - High 13.58:1 (570)

Drive Ratio - Front 3.818:1

Tire Size - Front 25 x 8 - 12

Tire Size - Rear 25 x 11 - 12

Tire Pressure - Front 10 psi (69 kPa)

Tire Pressure - Rear 10 psi (69 kPa)

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

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

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

Indicator Light 1.0 W

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SPECIFICATIONS

RANGER CREW 570 MaximumWeight Capacity (includes weight of operator, passenger, cargo, accessories)

1250 lbs. (567 kg)

Dry Weight 1323 lbs. (600 kg) (570) 1352 lbs. (613 kg) (570 EPS)

Test GVW - Rollover Protection System (ROPS)

2700 lbs. (1225 kg) per OSHA 29 CFR 1928.53

Fuel Capacity 8.8 gal. (33.3 l)

Engine Oil Capacity 2 qts. (1.9 l)

Coolant Capacity 170 oz. (5 l)

Overall Length 142 in. (360.7 cm)

Overall Width 60 in. (152.4 cm)

Overall Height 73 in. (185 cm)

Wheelbase 73 in. (185 cm)

Cargo Box Dimensions (Inside) 32x42x11.5 in. (81x107x 9 cm)

Ground Clearance 10 in. (25.4 cm)

Min. Turning Radius 237 in. (602 cm)

Towing Capacity 1500 lbs. (680.4 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load 500 lbs. (227 kg)

Engine Dual overhead cam, 4 valve 4 stroke single cylinder.

Displacement 567 cc (570)

Bore x Stroke (mm) 99mm x 73.6mm (570)

Alternator Output 560 W@ 3000 RPM

Compression Ratio 10:1 (570)

Starting System Electric

Fuel System Electronic Fuel Injection

Ignition Timing ECU Controlled 32 +/- 2 @ 5000 RPM

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SPECIFICATIONS

Spark Plug NGK MR7F / .031 (0.7-0.9 mm)

Lubrication System Wet Sump

Cooling Liquid

Front Suspension McPherson Strut w/8 in. (20.3 cm) of travel (570)

Rear Suspension Independent (23 cm) of travel (570)

Throttle Body Size 42 mm (570)

Ignition System Digital CDI

Driving System Type PVT

Shift Type Single Lever (console)

Gear Reduction - Low 28.84:1

Gear Reduction - Reverse 25.83:1

Gear Reduction - High 13.58:1

Drive Ratio - Front 3.818:1

Tire Size - Front 25 x 10 - 12

Tire Size - Rear 25 x 10 - 12

Tire Pressure - Front 10 psi (69 kPa)

Tire Pressure - Rear 14 psi (96 kPa)

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

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

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

Indicator Light 1.0 W

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SPECIFICATIONS

POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS

PRODUCT SIZE (QUANTITY) PART NUMBER

Fogging Oil 12 oz aerosol (12) 2870791

1 qt (12) 2871517

PS-4

1 qt (12) 2876244

2 qt (8) 2877490

1 gal (4) 2876245

PS-4 Extreme Duty

1 qt (12) 2878920

2 qt (8) 2878922

1 gal (4) 2878919

AGL 1 qt (12) 2878068

1 gal (4) 2878069

Pump for Gallon Jug 3.8 l 2870465

Demand Drive 1 qt (12) 2877922

2.5 gal (2) 2877923

Antifreeze / Coolant 1 qt (12) 2880514

1 gal (6) 2880513

Grease Gun Kit, Premium All Season 2871312

All Season Grease Four 3 oz packs (6) 2871322

14 oz cartridge 2871423

Premium Starter Grease 2871460

U-Joint Grease 3 oz tube (24) 2871515

14 oz cartridge 2871551

Dielectric Grease (Nyogel) 2871329

Carbon Clean 12 oz bottle (12) 2871326

Fuel Stabilizer 16 oz (12) 2870652

2.5 gal (2) 2872280

DOT 4 Brake Fluid 2872189

Loctite 565 Thread Sealant 2871956

POLARIS Battery Tender Charger 2859044

139

POLARIS PRODUCTS

140

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.

Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently.

Insufficient warm-up at low ambient temperatures

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

Slow/easy clutch engagement 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 rollover.

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 rollover.

Belt slippage from water or snow ingestion into the PVT system

Dry out the PVT. Prevent water from entering the PVT intake duct. See Intake Pre-Filters for more information. Inspect clutch seals for damage if repeated leaking occurs.

Clutch malfunction An authorized dealer can assist.

Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines. An authorized dealer can assist.

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.

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TROUBLESHOOTING

ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION

Low battery voltage Recharge the battery

Loose battery connections Check all connections and tighten

Loose solenoid connections Check all connections and tighten

Loose electronic control box connections

Inspect, clean, reinstall connectors

ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

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 plug Inspect plug and replace if necessary

No spark to spark plug Inspect plug and replace if necessary

Water or fuel in crankcase Your authorized dealer can assist

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure Your authorized dealer can assist

ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION

Weak spark from spark plug Inspect, clean and/or replace spark plug

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

Old or non-recommended fuel Replace with fresh recommended fuel

Incorrectly installed spark plug wires

Your authorized dealer can assist

Mechanical failure Your authorized dealer can assist

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with fresh recommended fuel

142

TROUBLESHOOTING

ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION

Poor quality or low octane fuel Replace with recommended fuel

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES

POSSIBLE CAUSE SOLUTION

Fouled or defective spark plug Inspect, clean and/or replace spark plug

Worn or defective spark plug wires

Your authorized dealer can assist

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

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

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

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

Other mechanical failure Your authorized dealer can assist

ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Kinked or plugged fuel vent line

Inspect and replace

Water is present in fuel Replace with new fuel

Fouled or defective spark plug Inspect, clean and/or replace spark plug

Worn or defective spark plug wires

Your authorized dealer can assist

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

143

TROUBLESHOOTING

POSSIBLE CAUSE SOLUTION

Loose ignition connections Check all connections and tighten

Low battery voltage Recharge the battery

Incorrect fuel Replace with fresh recommended fuel

Clogged air filter Inspect and clean or replace

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

Other mechanical failure Your authorized dealer can assist

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

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TROUBLESHOOTING

WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a ONE YEAR LIMITED WARRANTYon all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. 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 your proof of warranty coverage. 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 trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

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

Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Filters Lubricants Bushings

Finished and unfinished surfaces Carburetor/Throttle body components

Engine components Drive belts Hydraulic components and fluids Circuit breakers/Fuses Electronic components Spark plugs Sealants Coolants Bearings

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WARRANTY

LUBRICANTS AND FLUIDS 1. Mixing oil brands or using non-recommended oil may cause engine damage.

We recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OFANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTYARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOTAPPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

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WARRANTY

HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.

IN THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer, or other qualified person. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer, or other qualified person, that sells the same line as your product.

OUTSIDE THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer, or other qualified person. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

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

IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

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WARRANTY

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

NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Dealership contacts can be found via this website, if needed:

www.polaris.com/en-us/contact 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 or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

To report a safety defect to Transport Canada, you may either fill out an online defect complaint form at their website: English: http://www.tc.gc.ca/recalls French: http://www.tc.gc.ca/rappels

Or contact their Defect Investigations and Recalls Division by calling toll-free 1- 800-333-0510 (Canada) or 819-994-3328 (Ottawa-Gatineau area / International).

149

WARRANTY

U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.

The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension.

This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

Air-induction system Fuel system

Ignition system Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

Aftertreatment devices Crankcase ventilation valves

Sensors Electronic control units

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WARRANTY

The following parts are considered emission-related components for evaporative emissions:

Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls*

Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector

*As related to the evaporative emission control system.

Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTYARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES 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 inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. 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 when the vehicle 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.

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WARRANTY

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

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

CALIFORNIA RESIDENTS Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50- state models available for sale in California are identified by the letter B in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer.

The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreational Vehicle in California if the vehicle is equipped with an evaporative emission control system and is labeled with a Vehicle Evaporative Emissions Control Information label indicating that the vehicle conforms to California evaporative emissions regulations applicable to new off-road sport vehicles, all-terrain vehicles, or off-road utility vehicles. These vehicles are referred to as OHRV-EVAP below.

CALIFORNIA EMISSION CONTROLWARRANTY STATEMENT YOURWARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Polaris Industries Inc. is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's stringent anti-smog standards. Polaris must warrant the emission control system on your OHRV-EVAP for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your OHRV-EVAP.

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WARRANTY

Your emission control system may include parts such as the carburetor or fuel injection system, fuel tank, fuel hoses, carbon canister, engine computer and Evaporative Emissions Control System parts listed in the U.S.A. EPA Emissions Limited Warranty. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, Polaris will repair your OHRV-EVAP at no cost to you including diagnosis, parts and labor.

MANUFACTURERS WARRANTY COVERAGE: For model year 2018 and newer OHRV-EVAP models.

For 30 months, or 2500 miles, or 250 hours, whichever comes first, except for evaporative components over the OHRV high-priced warranty value, which is covered for 60 months, or 5000 miles, or 500 hours, whichever comes first.

If any emission-related part on your OHRV-EVAP is defective, the part will be repaired or replaced by Polaris.

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

ADD-ON OR MODIFIED PARTS An add-on or modified part must be compliant with applicable CARB emission control standards. A violation of this requirement is punishable by civil and/or criminal punishment.

If you have any questions regarding your warranty rights and responsibilities, you should contact Polaris Customer Assistance at 1-800-POLARIS (1-800-765- 2747) or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

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WARRANTY

154

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

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

155

MAINTENANCE LOG

156

A Active Descent Control ............... 74 Adding or Changing Coolant ...... 104 Age Restrictions ........................ 25 AGM Battery Charging.............. 125 Air Filter..................................112 Air Filter / Air Box..................... 129 All Wheel Drive (AWD) System..... 70 All Wheel Drive/Rear Differential System ................... 70 Auxiliary Outlet.......................... 36 AWD/ADC Drive Mode Switch ...... 38 AWD/Differential Lock Switch ....... 37 Axle and Wheel Nut Torque Specifications.........................119

B Battery Charging ............................ 125 Installation .......................... 124 Overview ............................ 124 Removal ............................. 124

Battery Maintenance ................ 130 Belt Life ................................... 67 Belt Replacement / Debris Removal .............................. 108 Boots ...................................... 15 Brake Lights ........................... 123 Brake Pedal ............................. 41 Brake System Break-in ............... 56 Brakes ...................................115 Braking ................................... 59 Break-in Period ......................... 55

C Cab Doors ............................... 26 Cab Nets ................................. 44 California Residents ................. 152 Carrying a Passenger................. 27 Charging the Battery ................ 125 Chrome Wheel Care (if equipped)............................. 128 Clean the Exterior .................... 129

Clock Mode .............................. 51 Clothing................................... 15 Clutch Cover Alert ..................... 24 Cold Weather Operation.............. 58 Component Locations................. 35 Cooling System....................... 104 Crankcase Emission Control System .................................. 87 Crossing Hillsides ...................... 29

D Descending Hills Improperly ........ 29 Diagnostic Display Mode............. 52 Disengaging AWD ..................... 70 Drive Belt Wear/Burn................ 141 Driving Downhill ........................ 63 Driving in Reverse ..................... 64 Driving on a Sidehill ................... 63 Driving Through Water................ 64 Driving Uphill ............................ 63 Dumping the Cargo Box .............. 69

E Electromagnetic Interference ....... 87 Electronic Power Steering ........... 41 Emissions Limited Warranty....... 150 Engaging/Disengaging AWD........ 70 Engine and Drivetrain Break-in ..... 55 Engine Backfires ..................... 142 Engine Doesn't Turn Over ......... 142 Engine Oil ................................ 94 Engine Pings or Knocks ............ 143 Engine Runs Irregularly, Stalls or Misfires ............................ 143 Engine Stopping........................ 59 Engine Stops or Loses Power .... 143 Engine Turns Over, Fails to Start .................................... 142 European Vibration and Noise ...... 11 Exhaust Emission Control System .................................. 87 Exported Products ................... 149 Exposure to Exhaust .................. 33 Extreme Use 30 AH Battery ......... 45

157

Eye Protection .......................... 15

F Failure to Inspect Before Operating ............................... 26 Fan, Cooling........................... 104 Fluid Levels............................ 129 Fluid Part Numbers .................. 139 Fog the Engine ....................... 130 Front Gearcase (Demand Drive) .................................. 100 Fuel Cap.................................. 44 Fuel Safety............................... 33 Fuel Stabilizer......................... 129 Fuse Box Diagram ................... 121 Fuses ................................... 121

G Gasoline Handling ..................... 33 Gauge Display Units ......................... 50 Engine Error Codes ................ 53 Engine Hours......................... 51 Mode Button.......................... 50 Odometer ............................. 51 Tachometer ........................... 52 Trip Meter ............................. 51

Gear Selector ........................... 39 Gearcase Specification Chart ..... 101 General Alert (7183794).............. 22 Gloves .................................... 15

H Hauling Cargo........................... 66 Headlight Beam Adjustment....... 123 Headlight Lamp Replacement .... 122 Helmet .................................... 15 Hitch Capacity Alert (7183975) ..... 24 Hot Exhaust Systems ................. 33 How To Obtain Warranty Service ................................ 148

I Ignition Switch .......................... 37 Improper Cargo Loading ............. 34 Improper Tire Maintenance .......... 28 Indicator Lamps ........................ 47 Inspect and Lubricate ............... 129 Instrument Cluster ..................... 46 Israel Model Differences................7

K Know Your Riding Area/Tread Lightly ................................... 58

L Lights.................................... 122 Limited Warranty ..................... 145 Low Gear................................. 40 Lubricants / Service Products ..... 139 Lubrication Recommendations ..... 93

M Maintenance Chart Key .............. 90 Maintenance Log..................... 155 Maintenance, Periodic ................ 89 Maximum Payload Warning ......... 16 Modifications to Vehicle .............. 34

N New Operator Driving Procedures............................. 60 Noise Emission Control System.... 87 Notice ................................... 149

O Obstacles ................................ 62 Oil and Filter ........................... 129 Oil and Filter Change.................. 96 Oil Check................................. 95

158

Oil Recommendations ................ 94 Operating Improperly in Reverse... 30 Operating Over Obstacles ........... 31 Operating Through Water ............ 31 Operating With a Load on the Vehicle .................................. 27 Operation Driving Over Obstacles ............ 62 Driving with a Passenger.......... 61 Slippery Surfaces ................... 62

Operation on Public Lands in the U.S.A................................ 87 Operator Safety......................... 20 Overflow Bottle Coolant Level .... 106

P Park Brake Lever....................... 42 Parking on an Incline .................. 65 Parking the Vehicle ............... 59, 65 Part Numbers ......................... 139 Passenger / Tire Pressure Warning ................................. 23 Passenger/Tire Pressure Warning ................................. 19 Periodic Maintenance Chart ......... 89 Plugs, Spark........................... 102 Polaris Products ...................... 139 POLARIS Variable Transmission (PVT) System PVT Drying ............................110 POLARIS Variable Transmission System.............. 107 Polishing the Vehicle ................ 128 Poor Visibility............................ 32 Power Steering ......................... 41 Power Steering Unit (Cleaning)....118 Pre-Ride Inspection ................... 56 Programmable Service Interval..... 52 Proper Use Warning................... 18 Protective Apparel ..................... 26 PVT Break-in (Clutches/Belt) ....... 56

R Radiator and Cooling Fan.......... 104

Radiator Coolant Level ............. 105 RANGER CREW 570 Specifications........................ 137 Registration, Warranty .............. 145 Removal from Storage.............. 130 Removing Corrosion ................ 128 Reverse Operation..................... 64 Rider Information Center ............. 48 Rollover Protective Structure (ROPS).................................. 45

S Safe Operation Practices ............ 57 Safe Riding Gear....................... 13 Safety Labels............................ 17 Fuel Transport Warning............ 18

Safety Labels and Locations ........ 16 Safety Symbols ...........................4 Safety Training.......................... 13 Safety Warnings........................ 25 Safety, Winch Maintenance.......... 85 Seat Belt.................................. 43 Seat Belt / Drive Responsibly Warning ................................. 17 Seat Belts ................................ 26 Seat Removal ........................... 42 Shift Alert (7183987) .................. 22 Shock Loading the Winch ............ 84 Signal Words ..............................4 Spark Arrestor .........................114 Spark Plug Gap/Torque............. 102 Spark Plug Inspection............... 102 Spark Plug Recommendations ... 102 Specifications RANGER 500 ...................... 133 RANGER 570/570 EPS ......... 135

Stabilize the Fuel ..................... 129 Stalling While Climbing a Hill ........ 30 Standard Turf Switch .................. 38 Starting the Engine .................... 58 Steering Wheel ......................... 40 Steering Wheel Inspection..........118 Stopping the Engine................... 59 Storage ................................. 128 Storage Area .......................... 130 Suspension Adjustment .............117

159

Switches AWD Switches ....................... 37

T Tire Tread Depth ..................... 120 Tires ......................................119 Towing Loads ........................... 68 Trail Etiquette ........................... 58 Trailer Hitch Bracket................... 45 Transmission ............................ 98 Transporting the Vehicle............ 131 Turning Improperly..................... 29

U Unauthorized Use of the Vehicle ... 34

V Vehicle Identification Numbers ..... 10 Vehicle Immersion .................... 111

W Warning Symbols ........................4 Washing the Vehicle................. 127 Welcome Page ...........................3 Wet Fouled Plug...................... 103 Wheel Installation .................... 120 Wheel Removal....................... 120 Winch Cable Care ..................... 83 Winch Maintenance and Service Safety ......................... 85 Winch Operation ....................... 78 Winch Safety Precautions ........... 75 Winch Shock Loading................. 84

160

For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com

Polaris Industries Inc. 2100 H

Manualsnet FAQs

If you want to find out how the 570 Polaris works, you can view and download the Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Polaris 570 as well as other Polaris manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Polaris 570. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Polaris Ranger 500, 570, Crew 570 v3 Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.