Polaris 2005 99 Ranger Owner'S Manual Download

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MAINTENANCE

Lubrication Recommendations

Item

Lube Rec.

Method

Frequency*

1.Engine Oil

Polaris Pre-
mium 4 Syn-
thetic 0W40

Add to proper level on dipstick.
See page 37.

Check level dai-
ly.

2. Brake Fluid

DOT 3 Only

Maintain level between fill lines.
See page 78.

As required;
change every
two years or 200
hours

3. Transmission

Oil

Polaris Pre-
mium Syn-
thetic chain
case lube

Add to FULL level on dipstick.
See page 66.

Change annually
or at 100 hours

4. Front Gear-
case Oil

GL5 80-90
Weight Gear
Lube

Fill to bottom thread of filler hole.
Make certain machine is on level
surface.

Change annually

5. Center Half-
shafts

Grease

Locate Fittings and Grease

Every 3 months
or 50 hours

6. Front Prop
Shaft U-joints

Grease

Locate Fittings and Grease

Every 3 months
or 50 hours

7. Front Prop-
shaft Yoke

Grease

Locate fittings and grease – 3
pumps maximum

Every 3 months
or 50 hours

8. Demand 6

Hubs - All
Wheel Drive

Premium
Hub Lube

Remove set screw in hubs. Ro-
tate wheels to 4 O’clock position.
If lubricant is not visible add more.
Reinstall set screw.

Annually or at
100 hrs

9. Front Drive

Axle (U Joint)

Grease

Locate grease fitting and grease
with grease gun.

Every 3 months
or 50 hours

10. Ball Joint

Grease**

Locate fitting on back side of
struts and grease with grease
gun.

Every 3 months
or 50 hours

Summary of Contents for 2005 99 Ranger

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Page 3: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 4: ... provide you with the best service possible PROTECT YOUR SPORT Know all local state province off road vehicle laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as outlined This preventive maintenance program is designed to ensure that all criti cal components on this vehicle are thorou...

Page 5: ... alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your vehicle each time you use it to make sure it is in safe operat ing condition Always follow the inspection and maintenance procedure...

Page 6: ... Never operate vehicle in fast flowing water or in water deeper than that specified in this manual Remember that 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 you when you operate in reverse When it is safe to proceed in reverse g...

Page 7: ... safety hazard Polaris hereby informs you that the warranty on your RANGER is terminated if any such equipment has been added to the vehicle or any modifications have been made to the vehicle which increase its speed or power We also advise you to strictly follow the recommended maintenance program out lined in this manual This preventive maintenance program is designed to ensure that all critical...

Page 8: ...y insurance for you Polaris vehicle The toll free insurance telephone number is 1 800 473 0111 The chance to arrange travel through the Polaris Travel Center The toll free travel telephone number is 1 800 267 1915 The chance to apply to serve on PRO Consumer Councils that provide input into the Polaris vehicles of the future The chance to serve as a PRO Field Evaluator and provide feedback on your...

Page 9: ...RATION WARNINGS 10 19 VEHICLE IDENTIFICATION NUMBERS 20 CONTROL AND PARTS FUNCTIONS 21 39 STARTING THE ENGINE 40 43 VEHICLE BREAK IN PERIOD 44 CARRYING LOADS 45 OPERATION SAFETY 46 55 NOISE EMISSION CONTROL SYSTEM REGULATION 56 BATTERY 571 58 MAINTENANCE 59 88 TROUBLE SHOOTING 89 SPECIFICATIONS 90 91 WARRANTY 92 93 INDEX 94 ...

Page 10: ...ich could result in serious injury or death CAUTION Indicates a potential hazard which may result in minor personal inju ry or damage to the vehicle NOTE The word NOTE in this manual will alert you to key information or instructions WARNING HAZARD Failure to heed WARNINGS WHAT CAN HAPPEN WARNINGS identify special instructions or procedures which if not cor rectly followed could result in personal ...

Page 11: ... death l Never carry riders in cargo box IMPROPER TIRE PRESSURE OR OVER LOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT MIN 5 MAX 12 CENTER REAR MIN 5 MAX 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE PASSENGER AND CARGO IS 2920 LBS SEE OWNER S MANUAL FOR PROPER TIRE INFLATION FOR DIFFERENT VEHICLE APPLICATIONS TRAI...

Page 12: ... ONE passenger only Ce Vehicule est concu pour ne transporter que le conducteur et UN SEUL passager HEADLAMPS ARE NOT SEALED DO NOT SUBMERGE OR APPLY WATER PRESSURE DIRECTLY ONTO SERVICE OPENING WARNING DO NOT ATTEMPT ENGINE OR CLUTCH MODIFICATION DOING SO CAN CAUSE IMBALANCE AND OR EXCESSIVE ENGINE RPM EXCESSIVE ENGINE RPM CAN CAUSE PART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH DO NOT...

Page 13: ... used as an EMERGENCY OR PARKING BRAKE ONLY THE BOX DUMP LATCH MUST BE SECURELY LATCHED before loading and op erating Unintentional box dumping will result if weight is placed in the rear of the box and the latch is not secured NEVER OPERATE THIS VEHICLE WITH THE DUMP BOX IN THE RAISED POSITION The dump box could close unexpectedly while driving severely injur ing the driver and passenger The rear...

Page 14: ... CARRYING CARGO MAXIMUM CARGO CAPACITY IS 1000 LBS ON LEVEL TERRAIN When oper ating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions When operating at maximum cargo capacity the cargo weight must be evenly distributed in the rear box ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in...

Page 15: ...censed operators increases the risk of severe injury or death MINIMUM AGE RECOMMENDATION FOR PASSENGERS IF FIVE YEARS OLD Passengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seat belts at all times THIS VEHICLE CAN BE HAZARDOUS TO OPERATE A collision or rol lover can occur quickly even during routine maneuve...

Page 16: ...ways avoid paved surfaces NEVER OPERATE THIS VEHICLE AT EXCESSIVE SPEEDS You in crease your risk of losing control if you operate this vehicle at speeds too fast for the terrain visibility conditions or your experience HELMETS ARE RECOMMENDED WHENEVER DRIVING THIS VEHICLE IN AN AGGRESSIVE MANNER Eye protection is recommended at all times See Owner s Manual REVERSE OPERATION CAN BE DANGEROUS Steeri...

Page 17: ...8 LABEL LOCATION 2 4 6 5 1 3 1 Warning General 2 Warning Vehicle roll over 3 Warning Load Distribution 4 Warning Cargo Bed 5 Tire Pressure 6 Towing Information ...

Page 18: ...stment and fluid level includes emergency parking brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine ignition switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element check for dirt clean or replace ...

Page 19: ...and all warning and instruc tion labels on the vehicle POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle WHAT CAN HAPPEN Use of this vehicle by a child can lead to severe injury or death of the child or others Even though a child may be within the age group for which some vehicles are recommended he or she may not have the skills abilities or judg ment needed to operate t...

Page 20: ...lots and streets WARNING Safe operation of this vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN You can collide with anot...

Page 21: ... perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this vehicle POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Increases your chances of losing control of the vehicle which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operatin...

Page 22: ...WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when ...

Page 23: ...n until you have learned and practiced the skills necessary to control the ve hicle on such terrain Always be especially cautious on these kinds of terrain WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the RANGER on hills too stee...

Page 24: ...IAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Im...

Page 25: ... vehicle You may also regain traction unexpectedly which may cause the vehicle to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator break through the...

Page 26: ...se WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD Before you select reverse gear make sure there are no obstacles or people behind you When it is safe to proceed go slowly Always avoid backing down hill WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use ...

Page 27: ...on this vehicle and should be installed and used according to instructions If you have questions consult an authorized Polaris dealer WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Could result in vehicle overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Apply the brakes Lock parking brake after y...

Page 28: ...braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See page 45 WARNING WARNING Never carry passengers in the box If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward the box will want to dump on its own Never operate the dump lever without checking the position of the load This will pre...

Page 29: ... number found stamped on the key In the event the key is lost replacement can be made by supplying your dealer with this number Ignition Key Number The vehicle frame and engine serial numbers are important for model identifica tion when registering your vehicle obtaining insurance or whenever replace ment parts are required In the event your vehicle were stolen these numbers are essential to the r...

Page 30: ...return to the ON position Do not operate the starter continuously for more than 5 seconds or the start er will overheat and the battery power will drop temporarily Wait at least 5 seconds between each operation of the starter to let it cool and the batter power recover Do not turn the ignition switch key to the START position with the engine run ning or damage to the starter can result Light Switc...

Page 31: ... board Depress the brake pedal to slow or stop the ve hicle WARNING Once a bottle of brake fluid is opened use what is neces sary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of ...

Page 32: ... the center of the buckle Steering Wheel The steering wheel position can be adjusted to suit the operator 1 Loosen the bolt and nut 1 on the steering column bracket and move the steering wheel up or down to desired height 2 Tighten the bolts and nuts Throttle Pedal The throttle pedal is the right pedal on the floor board Push the pedal down to in crease engine speed Spring pressure returns the ped...

Page 33: ...ly exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on re serve gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to on posi tion after refueling machine Gasoline and Alcohol Blends Blends of gasoline and alcohol called gasohol can be used on an occasional basis however continued use is not recom mended Switch back immedi a...

Page 34: ...sparks in or near the area where refueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you should get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline pow ered engine exhaust fumes are poisonous and can cause loss of con sciousness a...

Page 35: ...hanol wood alcohol Gas oline containing methanol must also be blended with cosolvents and corrosion in hibitors Never use gasohol for extended periods and never store this vehicle with gasohol in the fuel system Gasoline containing alcohol can cause paint damage Be extra careful not to spill gasohol during refueling WARNING The engine exhaust from this product contains chemicals known to cause can...

Page 36: ...View 1 Cab Frame 2 Cab Frame Hand Hold 3 Dashboard 4 Steering Wheel 5 Gear Shift Lever 6 Seat 7 Cargo Box 8 Seat Belts 9 Parking Brake 10 Engine Compartment Access Panel 11 Hood Latches attached to hood left and right sides under dash 1 10 4 8 6 7 9 11 5 2 3 ...

Page 37: ...28 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Front View 14 16 15 13 12 12 12 Headlights 13 Air Box under hood 14 Battery under hood 15 Radiator under hood 16 Front Bumper Brush Guard ...

Page 38: ...29 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Rear View 17 18 21 20 19 17 17 Tail Gate Latches Top and Bottom 18 Tail Gate 19 Muffler Spark Arrester 20 Trailer Hitch Receiver 21 Taillight ...

Page 39: ... 3 7 5 6 9 4 10 1 Choke Knob 2 Ignition Switch 3 Hour Meter 4 Passenger Warning Decal 5 Neutral Indicator Light 6 Reverse Indicator Light 7 Brake Light 8 Coolant Temperature Warning Light 9 Fuel Gauge 10 12V Accessory Plug 11 Fog High Beam Light Switch 12 AWD All Wheel Drive Switch ...

Page 40: ...ally disengage The AWD button position and a red AWD light indicates when the vehicle is in De mand 6 Drive There is no limit to the length of time the vehicle may remain in De mand 6 Drive The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction CAUTION Do not switch o...

Page 41: ...ired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer WARNING 1 Do not attempt to shift the transm...

Page 42: ... death If the hubs remain engaged after following these instructions return the vehicle to your dealer for service PVT System WARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been con ducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this syste...

Page 43: ...re cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purg ing itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the ...

Page 44: ...tem to function properly If the cap should need replacement contact your dealer for the correct replacement part Drain Plug Locations The oil should be changed annu ally especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky appearance it should be changed as soon as possible Failure to properly maintain this i...

Page 45: ... water be added Polaris recommends the use of Polaris Pre mium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum com patible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water IMPORTANT Al ways follow the manufacturer s mixing recommendations for the freeze protection required in your area Using a fun...

Page 46: ...d to be changed more fre quently if Polaris Premium 4 is not used You will also need to follow the manufac turers recommendations for ambient temperature operation Oil System The oil tank is located on the left side of the vehicle To check the oil 1 Set machine on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine remove dipstick 1 and wipe dry with a clean clot...

Page 47: ...remove the drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 6 Allow oil to drain completely 7 Install a new sealing washer PN 5850135 on oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 8 Reinstall drain plug and torque to 14 17 ft lbs 1 93 2 35 kg m 9 Pl...

Page 48: ...arking brake 17 Start engine and let it idle for one to two minutes Stop engine and inspect for leaks 18 Re check oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 19 Dispose of used filter and oil properly Fuel Filter and Oil Filter Your Polaris RANGER is equipped with a unique in line fuel filter These filters should be replaced by your deale...

Page 49: ... in severe injury or death Always contact your dealer for service repairs whenever throttle prob lems arise Failure to check or maintain proper operation of the throttle system can result in the throttle pedal sticking during driving and cause an accident Always check the pedal for free movement and return before starting the engine and occasionally during driving 1 Place the transmission in neutr...

Page 50: ...er the Engine Starts 1 If the engine slows or stops use of the choke lever at its HALF position will allow proper engine warm up 2 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Then move the choke to OFF CAUTION Proper engine warm up is essential each time before driving to avoid engine damage WARNING Carbon monoxide exhaust gas is poisonous Alway...

Page 51: ... in the vehicle in the driver s seat 5 Turn the ignition key to START HALF OFF Choke Lever Side View 6 If the engine has cooled to a point where it does not readily start intermittent use of the choke lever in its HALF position is permitted 7 If the engine is over choked by mistake when warm depress the throttle lever fully while cranking to aid in starting 8 Release the throttle lever immediately...

Page 52: ...e parking brake is set See page 27 2 Remove right side engine access panel See page 35 3 Grasp the recoil starter tightly and pull slightly until the starter mechanism en gages 4 Pull the rope abruptly to start the engine CAUTION Take care not to extend the starter rope so far that it stops causing damage to the recoil assembly CAUTION Never start the engine with the battery disconnected Damage to...

Page 53: ... or leaded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil reservoir level in dicated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and will give you room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle CAUTION Do not operate at full throttle or high speeds for ex...

Page 54: ...um vertical hitch weight 150 lbs 68 1 kg Use of low forward is recommended in heavy pulling situations to extend belt life Maximum grade while trailer towing 15 do not tow any trailer on a grade steeper than 15 Total Towed Load Weight level ground Total Towed Load Weight 15 grade Total Hitch Vertical Weight Towing Speed 1500 lbs 681 kg 850 lbs 386 kg 150 lbs 68 1 kg 10 mph 16 kph or less Do not ca...

Page 55: ...of the box damaging the vehicle and creating haz ardous driving conditions Do not carry more than 1000 Lbs in the cargo box Parking the RANGER 1 Stop the vehicle on a level surface CAUTION Avoid parking on steeply inclined surfaces 2 When the engine has stopped apply the parking brake to help prevent the ve hicle from rolling WARNING Be sure to apply the parking brake before leaving the vehicle If...

Page 56: ...cargo or towing a trailer remember that load weight will in crease braking distances Failure to allow for increased braking distance may result in accident and injury 1 Always load the cargo bed placing the load as far forward as possible 2 Always operate the vehicle with extreme care especially when hauling or tow ing loads 3 Slow down and drive in D 1 Gear only 4 The cargo box dump latch must be...

Page 57: ...ery areas CAUTION Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur Before operating your vehicle on a frozen body of water be sure that the ice is thick enough to support the machine and its operator as well as the force that is created by a moving vehicle Severe injury or death can result if the vehicle and or its oper ator break through the ice WARNIN...

Page 58: ...en operating your RANGER in hilly terrain Whenever descending a hill always 1 Drive directly downhill 2 Slow down 3 Apply the brakes lightly to aid in slowing WARNING Loss of vehicle control due to excessive speed can occur Loss of control may result in serious injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 2 Keep both feet on the footrests 3 Procee...

Page 59: ...tes a potential hazard which could result in serious injury or death WARNING WARNING Avoid climbing steep hills Loss of vehicle control or overturning of vehicle could occur Use extreme care when operating your RANGER in hilly terrain WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the vehicle to overturn If at all possible avoid crossing the side of a st...

Page 60: ...lean sharply to one side Go straight down the hill where possible WARNING Climbing hills improperly can cause loss of control or cause vehicle to over turn Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly The vehicle could go out of control Never go over the top of any hill at high speed A...

Page 61: ...possible 4 After crossing dry the brakes by applying light pressure to the lever until brak ing action is normal Should your vehicle become immersed it will be necessary to take it to your dealer as soon as possible Do not start the engine Immersion of the vehicle can cause major damage if not correctly repaired WARNING Never try to cross any deep or fast flowing streams The large tires can cause ...

Page 62: ...e constantly alert for hazards such as logs rocks and low hanging branches WARNING Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obstacles Keep alert and constantly look for obstacles on the trail indicates a potential hazard which could result in serious injury or death WARNING ...

Page 63: ...e Always back slowly avoiding excessive speed Avoid backing on steep inclines Parking On An Incline Whenever the Vehicle is Parked 1 Place the transmission in gear 2 Set the parking brake 3 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side 4 Shut off fuel supply WARNING Always check to be sure that the parking brake has been dis...

Page 64: ...to dump WARNING If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward the box will want to dump on its own Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box WARNING Never carry passengers in the box WARNING In the event of an accident have a qualified service dea...

Page 65: ...E ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal reg ulations 4 Lack of proper maintenanc...

Page 66: ... clean rags Coat the terminals with dielectric grease or petro leum jelly Do not allow cleaning solution or tap water to enter the battery It will shorten the life of the battery Vehicle lamps may burn out if battery is disconnected during vehicle opera tion Also the reverse speed limiter can be damaged WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result fro...

Page 67: ...the order specified Red positive cable first black negative cable last 1 Set the battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte severe burns could result 3 First c...

Page 68: ...you are familiar with mechanical repair More often under severe use such as dirty or wet conditions Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genu ine Polaris parts available from your Polaris dealer Item Hours or Odometer Frequency Remarks Engine Oil Level Change 4 Cycle 100 hrs 1000 miles 6 months Check Level Daily Break in Se...

Page 69: ...0 hrs 12 months Clean out Recoil housing As required As required Drain moisture out after driving in water General Lubrication 30 hrs 3 months Lubricate all fittings pivots cables etc Front hubs fluid check AWD 50 hrs 6 months Check monthly Front hubs fluid change AWD 100 hrs 12 months Front Gearcase Oil 100 hrs 12 months Check monthly and change annually Transmission Oil Level 25 hrs Monthly Insp...

Page 70: ...Brake pad wear 10 hrs 100 miles Monthly Inspect periodically Parking Brake Pre Ride Pre Ride Check lever adjustment daily adjust Tires Pre ride Pre ride Inspect daily pre ride inspection item Wheels Pre ride Pre ride Pre ride inspection item Frame nuts bolts fasteners Pre ride Pre ride Pre ride inspection item CAUTION Due to the nature of these adjustments it is recommended that service be perform...

Page 71: ...rtain machine is on level surface Change annually 5 Center Half shafts Grease Locate Fittings and Grease Every 3 months or 50 hours 6 Front Prop Shaft U joints Grease Locate Fittings and Grease Every 3 months or 50 hours 7 Front Prop shaft Yoke Grease Locate fittings and grease 3 pumps maximum Every 3 months or 50 hours 8 Demand 6 Hubs All Wheel Drive Premium Hub Lube Remove set screw in hubs Ro t...

Page 72: ...ating Range Full 3 Transmission 6 Front Prop Shaft U Joint 9 Axle Cardan Front Drive AWD Models 5 Center Halfshaft U Joint 7 Propshaft Yoke Fill plug 4 Front Gear Case 10 Ball Joint 11 Front A Arm Pivot Shaft Upper 8 4 O clock position 8 Demand Hubs ...

Page 73: ...se Locate Fitting and grease Monthly or at 20 hours 17 Center and rear angle drives GL5 80 90 weight gear lube Fill to bottom thread of filler hole Make certain machine is on a level surface Monthly or at 20 hours More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Grease ...

Page 74: ...65 MAINTENANCE Lubrication Recommendations 13 Upper Control Arm 16 17 ...

Page 75: ...pstick 1 is located on the right side of the ma chine inside the chassis Transmission Oil The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually To check the transmission lubricant level you must first position the ve hicle on a level surface Remove the right engine access panel as de scribed on page 35 Rea...

Page 76: ...om right hand side and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug 4 Add Polaris Premium Syn thetic Gearcase Lubricant PN 2871478 to full mark on the fill plug dipstick 5 Check for leaks CAUTION Be careful not to allow any dirt or foreign materials to enter the trans mission case Full Operating Range ...

Page 77: ...NGER on a level surface remove fill plug and check the lubri cant level Lubricant should be kept at the bottom thread of the fill plug hole The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Gearcase Oil Changing Procedure 1 Remove fender panel 2 Remove fill plug dipstick 3 Remove gearcase drain plug located on the bottom right hand side and drain the oil Catch and discard used oi...

Page 78: ...ut Torque Specifications Front Spindle Nut s Dealer Performed Service Front Wheel Nuts 15 Ft Lbs Center and Rear Hub Retaining Nut s 120 Ft Lbs Rear Wheel Nuts 15 Ft Lbs Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op erations Service work must be performed by your authorized Polaris dealer ...

Page 79: ...od 2 Remove the cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter Do not attempt to clean the main element 4 Install new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Check air box If oil or water deposits are found drain them into a suitable con tainer NOTE Serv...

Page 80: ...n Check and clean the grille screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart CAUTION Using high pressure water as from a car wash facility could damage the radiator fins and impair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installing unauthorized ac cessories in front of the radiator or behin...

Page 81: ...ds the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compat ible anti freeze coolant and dis tilled water IMPORTANT Polaris Premium 60 40 is already pre mixed and ready to use Do not di lute with water IMPORTANT Al ways follow the manufacturer s mixing recommendations for the freeze protection required in your area NOTE In an emergency you can add wat...

Page 82: ...ments 2 Wet Fouled The 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 are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine...

Page 83: ...onto the incline so the front of the machine is one foot higher than the rear Set the park ing brake and block the wheels Make sure the machine is in neutral and repeat steps 2 and 3 WARNING SEE BELOW 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the arrestor plugs WARNING Because exhaust syste...

Page 84: ... ducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional ...

Page 85: ...ance with the Period ic Maintenance Chart and adjust the play if necessary Throttle Freeplay Inspection 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and warm it up thoroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should be 1 16 1 8 inches Adjustment If adjustment is necessary adjust t...

Page 86: ...conditions are favorable the carburetor can be adjusted as follows 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Warm up the engine by running the vehicle approximately five minutes 4 Remove the right hand engine compartment access panel and locate the idle screw 5 Place the transmission in gear with the parking brake applied 6 Adjust the carburetor idle screw in...

Page 87: ...round the fittings WARNING Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown WARNING Once a bottle of brake fluid is opened use what is necessary and dis card the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygro scopic meaning it rapidly absorbs moisture from the air This c...

Page 88: ... the nature of this type of vehicle and where it is operated headlight and taillight lenses may become dirty Frequent washing is necessary to maintain lighting quality Poor lighting while riding can result in severe injury or death CAUTION Do not service while lights are hot Serious burns may result Brake Light Switch When the brake pedal is depressed the brake light goes on Check the brake light ...

Page 89: ...cable and turn the nut next to the locknut 2 until the brake lever will only move 8 12 clicks upward Tighten the locknut securely NOTE Be sure to hold the cable end with a wrench to prevent the cable from twist ing Steering Wheel Check the steering wheel for specified free play and smooth operation in accor dance with the periodic maintenance Chart Inspection Park the vehicle on level ground Light...

Page 90: ...tallation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found on page 69 CAUTION I...

Page 91: ...for tire specifications Tire Specifications RANGER 6x6 Front 25 x 10 00 12 Inflation Pressure Min 5 Max 12 Center 25 x 11 00 10 Inflation Pressure Min 5 Max10 Rear 25 x 11 00 10 Inflation Pressure Min 5 Max 10 Cargo Box Load Capacity 1000 lbs 454 kg Gross Vehicle Weight 3020 lbs 1327 kg including vehicle driver passenger and cargo Vehicle weighs 1520 lbs 690 kg WARNING Operating your vehicle with ...

Page 92: ...ks The latch plate must slide smoothly into the buckle The click sound shows it is securely latched Push the red button in the middle of the buckle to make sure it releases freely Also check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked or replaced by an authorized Polaris dealer ...

Page 93: ...engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat 5 Loosen pivot bolts and adjust beam to desired position 6 Tighten nut and bolt Torque to 60 in lbs Indicator Lamp Replacement 1 Unplug light from harness depress loc...

Page 94: ...where gasoline is stored Do not over fill the tank If you should get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline pow ered engine exhaust fumes are poisonous and can cause loss of con sciousness and death in a short time Shut off fuel valve whenever the vehicle is stored or parked...

Page 95: ...any expensive repair bills can result from using high pressure detergent systems NOTE If a high pressure car wash is used grease all zerk fittings immediately af ter washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water Use a professional type was...

Page 96: ...o all tires are suspended off the ground 8 Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes 9 Lubricate all cables 10 Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals from entering 11 Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ve...

Page 97: ...noxide a colorless odorless poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Bolt and Nut Tightening Tightness of the bolts nuts and other fasteners should be checked by an autho rized Polaris dealer in accordance with the Periodic Maintenance Chart ...

Page 98: ...ve ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Water in Fuel Air Filter Clogged Fuel Vent Line Kinked or Plugged Clean Radiator screen Fu...

Page 99: ... H 40 x 59 75 x 9 Minimum Turning Radius 168 in Engine Oil Capacity 2 Quarts Coolant Capacity 2 25 Quarts Type 4 Cycle Single Cylinder Displacement 498 Bore x Stroke 90 x 75 Pilot Jet 42 5 Main Jet 125 Needle Jet Q 6 E Jet Needle 5D78 3 E N Air Screw 1 25 Turns N G Alternator Output 250 W I N Compression Ratio 10 2 1 Full Stroke N E Starting System Electric Start w Recoil Backup E Carburetor 1 BST...

Page 100: ...nces T I Tire Size Front 25 x 10 12 12 psi MAX I R E Tire Size Rear 25 x 11 10 10 psi MAX E S Tire Size Center 25 x 11 10 10 psi MAX Type Foot pedal activated hydraulic front and rear Mechanical Parking B R and rear Mechanical Parking Brake R A K Front Hydraulic disc Floating caliper K E S Rear Center Axle Hydraulic Disc floating Caliper S Parking Brake Hand Lever g Mechanical to center Axle L I H...

Page 101: ...92 WARRANTY ...

Page 102: ...e or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage nor mal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has ...

Page 103: ...RRANTY 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 War ranty 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 per...

Page 104: ...earcase Oil Changing Procedure 68 Indicator Lamp Replacement 84 Load Distribution 46 47 Lubrication Recommendations 62 65 Maintenance 59 88 Maintenance Schedule 60 61 Noise Control System 56 Oil Change 38 39 Oil Filter 39 Oil System 24 and 37 Operating Safety 46 55 Operation Warnings 10 19 Parking On An Incline 54 Premium 4 Synthetic Lubricant 37 PVT System 33 and 75 Rear Spring Adjustment 70 Reco...

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Polaris 2005 99 Ranger, Owner'S Manual

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Summary of Contents for 2005 99 Ranger

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