Polaris 2005 Ranger 4x4 Owner'S Manual For Maintenance And Safety Download

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

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TM
6X6

4X4
6X6

6X6

TM
6X6

Summary of Contents for 2005 Ranger 4x4

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

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Page 5: ... 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 Printed in U S A RANG...

Page 6: ... For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and i...

Page 7: ...y and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number behind left front wheel Frame VIN 1 under hood Engine Serial Number 2 right front side of engine crankcase Key Number 3 1 31XX 3 2 ...

Page 8: ...OME 3 VEHICLE IDENTIFICATION NUMBERS 4 SAFETY 7 FEATURES AND CONTROLS 25 OPERATION 34 EMISSION CONTROL SYSTEMS 52 MAINTENANCE AND LUBRICATION 54 POLARIS PRODUCTS 99 SPECIFICATIONS 100 TROUBLESHOOTING 106 WARRANTY 109 INDEX 117 ...

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Page 10: ...for anyone under 16 years of age No person under the age of 5 may ride as a passenger in this vehicle Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures...

Page 11: ...on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE...

Page 12: ...king on hills or during turns S This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces S Helmets are recommended whenever driving this vehicle in an aggressive manner Eye protection is recommended at all times S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Always travel at a speed proper for the ...

Page 13: ...l 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 pos sible S Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles S Always be ...

Page 14: ...n case of a sudden stop or collision S Always keep arms and legs inside the cab frame while the vehicle is in motion S Always apply the parking brake before getting out of the vehicle See page 33 S Always activate the foot pedal brake before releasing the park brake S Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or spar...

Page 15: ... We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase th...

Page 16: ...bing a hill If you lose all forward speed Apply the brakes Lock the parking brake after when fully stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering ...

Page 17: ...erating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations an...

Page 18: ...ighways WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will...

Page 19: ...rience WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE...

Page 20: ... follow the inspection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when op...

Page 21: ...les are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the ...

Page 22: ...ove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire ...

Page 23: ...n cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT ___ REAR ___ MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS _______ LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carrie...

Page 24: ... Never carry passengers in cargo box Maximum 2X4 TM Box Load 750 lbs 340 kg Maximum 4X4 Box Load 1000 lbs 454 kg Maximum 6X6 Box Load 1250 lbs 567 kg 1 2 3 4 Remove flammable containers from box before refueling WARNING WARNING WARNING Maximum Box Load is ___ lbs Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Location 4 inside front of box ...

Page 25: ...hicle without the filter element will severely damage the engine S Clean air filter often more frequent cleaning required in dusty conditions S Operation of this vehicle without en gine breather filter s can cause en gine damage Consult owner s manual for details S Specific carburetor jetting and adjust ments are required depending on temperature and altitude See your Owner s Manual Factory settin...

Page 26: ...ALWAYS S Avoid paved surfaces which may adversely affect handling and control S Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns S Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supply increased braking but should be used as ...

Page 27: ...ated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss ...

Page 28: ...uch as the cab frame Not all models come with all features Refer to the specifications section beginning on page 100 Component Locations 1 Cab Frame if equipped 2 Hip Bar 3 Console 4 Steering Wheel 5 Seat 6 Cargo Box 7 Seat Belts 8 Fuel Tank Cap Fuel Gauge 9 Battery 1 4 7 5 6 2 3 8 9 ...

Page 29: ...26 FEATURES AND CONTROLS Component Locations 10 Headlights 11 Radiator if equipped 12 Front Bumper Brush Guard 13 Hood Hold Down Strap 12 11 10 13 ...

Page 30: ...27 FEATURES AND CONTROLS Component Locations 14 Taillights 15 Tailgate 16 Tailgate Latch Release 17 Muffler Spark Arrester 18 CV Boot Rear Caliper 19 Air Box 20 Receiver Hitch 14 14 20 17 16 18 18 19 15 ...

Page 31: ...49 Auxiliary Outlet 1 The 12 volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Fuel Cap Fuel Gauge 2 The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat It has a built in fuel gauge that indicates the amount of fuel...

Page 32: ... death Always fasten your seat belt securely before operating or riding in the RANGER Passengers under five years of age require special restraints which are not available with this vehicle No person under the age of five years may ride in the RANGER To wear the seat belt properly follow this procedure 1 Place the belt across your lap as low on your hips as possible taking care that the belt is no...

Page 33: ...or Lights 3 Shift Lever 4 Light Switch 5 AWD Differential Switch if equipped 6 Hour Meter 7 Glove Box with Lid 8 12V Accessory Plug 9 Storage Tray 10 Choke Knob 11 Ignition Switch 12 Differential Lock Lever TM 13 Storage Box 11 10 6 2 8 12 3 7 13 1 4 5 1 9 ...

Page 34: ...e 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 See your dealer if you experience any shifting problems CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could r...

Page 35: ... vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Light Switch 2 The ignition switch key must be in the ON position to operate the headlights The switch has three positions A High Beam B Low Beam C Off AWD Differential Lock Switch 3 The AWD Differential Switch has three positions D AWD E Differential Lock F Off See page 33 for differential ...

Page 36: ...ase 4 To release the parking brake pull the release handle Spring pressure helps return the lever to the released position Make sure the parking brake lever is functioning properly before each operation Differential Lock Lever 5 and Switch 6 The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential It s beneficia...

Page 37: ...hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 1 Fill the fuel tank with gasoline Heed the gasoline warnings on page 24 2 Check the oil level on the dipstick See page 61 Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal safe op...

Page 38: ...nsure free operation Tires Inspect condition and pressure 88 103 Wheels fasteners Inspect ensure fastener tightness 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 61 64 Coolant level 4X4 6X6 Ensure proper level 72 Coolant hoses 4X4 6X6 Inspect for leaks Throttle Ensure proper operation 33 83 Indicator lights switches Ensure operation 28 32 Air filter pre f...

Page 39: ...Pull the choke knob 1 all the way out 2 NOTE Do not press the throttle pedal while starting the engine CAUTION Do not operate the starter continuously for more than five seconds or the starter will overheat and the battery power will drop temporarily Wait at least five seconds between each operation of the starter to allow it to cool and to allow battery power recovery Do not turn the ignition swi...

Page 40: ...rt intermittent use of the choke knob pulled half way out may be necessary 6 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts NOTE If the engine does not start and all conditions are favorable change the spark plug Stopping the Engine 1 Release the throttle pedal completely and...

Page 41: ... distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo Suspension Adjustment 4X4 The rear suspension of the RANGER 4X4 may be adjusted to provide a stiffer suspension if necessary The shocks are mounted to the inside mounting holes A at the factory but they may be relocated to the outsid...

Page 42: ...ing brake 5 Keeping both hands on the steering wheel slowly depress the throttle with your right foot and begin driving Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission PVT shifting is automatic 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces NOTE Low is the primary gear for operating the RANGER 4X4 and 6X6 High...

Page 43: ...eering wheel in the direction of the skid 4 Drive with AWD engaged if equipped to assist in controlling the vehicle CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss ...

Page 44: ...a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15_ maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never o...

Page 45: ...ow these precautions 1 Proceed directly downhill 2 Slow down 3 Apply the brakes slightly to aid in slowing WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly ...

Page 46: ...ly avoiding rocks and obstacles 4 After leaving water always dry the brakes by applying light pressure to the lever repeatedly until braking action is normal NOTE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 54 Give special attention to engine oil transmission oil front and rear gearcases and all grease...

Page 47: ...errain you re traveling on Watch for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain ...

Page 48: ...d backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly ...

Page 49: ...RNING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead Operating the vehicle while the parking brake is engaged could cause loss of control and result in serious injury or death Always disengage the p...

Page 50: ... in the lowest gear available The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels Never exceed the following capacities Maximum Capacities Level Ground Cargo Box RANGER 4X4 1500 lbs 681 kg 1000 lbs 454 kg RANGER 6X6 1750 lbs 794 kg 1250 lbs 567 kg RANGER TM 1250 lbs 681 kg 750 lbs 340 kg WARNING Dri...

Page 51: ...ile parked on an incline 2 Set the parking brake 3 Dismount the vehicle 4 Ensure that the cargo is positioned evenly or toward the front of the cargo box 5 Release the tailgate by pulling up on the tailgate latch 6 Stand clear and pull up on the cargo box release lever 1 7 Lift the front of the cargo box to dump the cargo 8 Lower the cargo box and push down securely to latch WARNING If the weight ...

Page 52: ...elow and the specifications charts beginning on page 100 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Maximum Towing Capacities Level Ground Total Towed Load Weight level ground Total Towed Load Weight 15 grade Total Hitch Vertical Weight Maximum Towing Speed RA...

Page 53: ...rface 2 When the engine has stopped apply the parking brake 3 Remove the ignition switch key to prevent unauthorized use WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pil...

Page 54: ...g they will not release until the rear wheels regain traction CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions it may be possible for one or both hubs to remain engaged unnecessarily This condition causes increased steering effor...

Page 55: ... to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The RANGER TM emissions label 1 is located on the front of the engine Remove the service panel 2 to view the label The label on the RANGER 4X4 and 6X6 3 is located on the recoil cover Remove the seat ...

Page 56: ...rements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 and Eu ropean 89 336 EEC ...

Page 57: ...jected to severe use must be inspected and serviced more frequently Severe Use Definition S Frequent immersion in mud water or sand S Racing or race style high RPM use S Prolonged low speed heavy load operation S Extended idle S Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or cr...

Page 58: ...visible Coolant if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if operating in wet conditions J Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean...

Page 59: ...e Cable ETC Switch 50 H 6 M Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M Inspect adjust replace as needed Cooling system if applicable 50 H 6 M Inspect coolant strength seasonally pressure test system yearly E Engine oi...

Page 60: ... needed J E Ignition Timing 100 H 12 M Inspect Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc J Clutches drive and driven 100 H 12 M Inspect clean replace worn parts J Front wheel bearings 100 H 12 M Inspect replace as needed J Brake fluid 200 H 24 M Change every two years Spark arrestor 300 H 36 M Clean out E Idle speed Adjust ...

Page 61: ...Engine Oil Polaris Premium 4 Synthetic 0W40 Add to proper level on dipstick Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines See page 84 Main Gearcase Oil Transmission Premium AGL Syn thetic Gearcase Lube Maintain as recommended on page 67 Front Gearcase Oil Premium Demand Drive Hub Fluid Maintain as recommended on page 68 Middle Gearcase Oil 6X6 only Premium ATV Angle Drive Fluid Main...

Page 62: ...59 MAINTENANCE AND LUBRICATION Lubrication Recommendations 1 2 TM 6X6 4X4 6X6 6X6 TM 6X6 ...

Page 63: ... to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambie...

Page 64: ...ds 3 Stop the engine and remove the seat see page 29 4 Remove the dipstick 1 and wipe it dry with a clean cloth 5 Reinstall the dipstick and screw it in completely NOTE The dipstick must be screwed in completely to keep the angle and depth of the stick consistent 6 Remove the dipstick and check to see that the oil level is between the full and add marks 2 Add oil if necessary Do not overfill NOTE ...

Page 65: ... scratches 5 Reinstall the drain plug and torque to 14 ft lbs 19 Nm 6 Loosen the clamp D and remove the oil hose from the screen fitting C on the bottom of the oil tank 7 Remove the screen fitting and clean the screen thoroughly 8 Apply Loctitet 565 Thread Sealant to the clean and oil free threads of the fitting 9 Reinstall the screen fitting and tighten to 14 ft lbs 19 Nm 10 Reinstall the oil hos...

Page 66: ...m 4 Synthetic Oil 18 Place the gear selector in neutral and set the parking brake 19 Prime the oil pump using the procedure below Then stop the engine and inspect for leaks 20 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 21 Dispose of used filter and oil properly Oil Pump Priming RANGER 4X4 6X6 This priming procedure must be p...

Page 67: ...hole 5 as needed Do not overfill NOTE A rising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is over the full mark change the oil Oil and Filter Change RANGER TM 1 Position the vehicle on a level surface 2 Run the engine two to three minutes until warm then stop the engine 3 Clean the area around the drain plug 6 at the bott...

Page 68: ...9 Check to make sure the o ring 3 is in good condition Lubricate the o ring on the new filter with a film of engine oil 10 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional 3 4 turn NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 11 Add 1 64 quarts 1550 ml of the recomm...

Page 69: ...ium AGL Synthetic Gearcase Lube 18 2 oz 540 ml 14 ft lbs 19 4 Nm 14 ft lbs 19 4 Nm Front Gearcase 4X4 6X6 Premium Demand Drive Hub Fluid 5 oz 150 ml 8 10 ft lbs 11 13 6 Nm 11 ft lbs 15 Nm Middle Gearcase 6X6 Premium ATV Angle Drive Fluid 6 75 oz 200 ml 14 ft lbs 19 4 Nm 14 ft lbs 19 4 Nm Rear Gearcase 4X4 Premium ATV Angle Drive Fluid 18 oz 532 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Rear Gea...

Page 70: ... add as needed 4 Reinstall the fill plug Torque to specification See page 66 Oil Change The drain plug 2 is located on the bottom of the transmission Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Remove the drain plug and drain the oil into a drain pan Dispose of used oil properly 3 Wipe the magnetic end of the drain plug clean to remove accumulated metall...

Page 71: ...vehicle on a level surface 2 Remove the fill plug and check the oil level 3 Add the recommended hub fluid as needed 4 Reinstall the fill plug Torque to specification See page 66 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 Remove the gearcase drain plug 2 located on the bottom right hand side and drain the oil into...

Page 72: ...the driver s side of the gearcase Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug and check the oil level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification See page 66 Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase and drain the oil into a drain pan Discard used oil properly 3 Clean and re...

Page 73: ... driver s side of the rear gearcase Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug and check the oil level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification See page 66 Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase and drain the oil into a drain pan Discard used oil properly 3 Clean and ...

Page 74: ...els and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality alumi...

Page 75: ...gh pressure system is used for washing the vehicle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 54 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle 1 is located in front of the right front wheel 1 Position the vehicle on level ground 2 View the...

Page 76: ...gine to cool before removing the pressure cap 1 Lift the hood and slowly remove the radiator cap 1 2 View the coolant level through the opening 3 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected NOTE Use of ...

Page 77: ... inspection 1 Normal 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 NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The w...

Page 78: ...bilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into t...

Page 79: ... 3 Remove the spark plug 4 Place a clean container under the engine and loosen the carburetor drain screw 1 two turns RANGER 4X4 6X6 RANGER TM 5 Turn the engine over several times with electric start Inspect the drained fuel for water or sediment 6 Dry the spark plug and reinstall or install a new plug 7 Tighten the carburetor drain screw 8 Reconnect the fuel pump wires 9 Attempt to start the engi...

Page 80: ...adhere tightly to the cover and seal all the way around 3 Remove the air filter 1 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container NOTE Service the air filter more frequently if th...

Page 81: ...o check for clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine and secure the clamps CAUTION Operation of the vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service Fuel Filter Your Polaris vehicle is equipped with...

Page 82: ...filter 4 and the secondary filter 5 NOTE Do not attempt to clean the primary filter Install new 5 Wash the secondary foam filter with hot soapy water Rinse and dry thoroughly 6 Inspect the filter for tears or damage Replace with a new filter if needed 7 Apply foam filter oil or clean engine oil and squeeze the filter until excess oil is removed 8 Reassemble all components Fuel Filter Your Polaris ...

Page 83: ...xhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never ...

Page 84: ...engine several more times 5 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 2 and 4 6 If particles are still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear...

Page 85: ...y also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 54 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Apply the parking brake 2 and shift the transmission to neutral 2 Start the engine and warm...

Page 86: ... Maintenance Chart or whenever the idle speed is changed Recommended engine idle RPM for the RANGER 4X4 and 6X6 is 1200 200 Recommended engine idle RPM for the RANGER TM is 1000 100 If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted with the following procedure 1 Engage the parking brake and place the gear shift lever in the neutral p...

Page 87: ...he fluid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir 1 under the hood The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings ...

Page 88: ...cessive wear 9 Change pads when worn to 3 64 1 cm Parking Brake Inspection 1 Slowly push the parking brake down with your foot 2 After 8 to 12 clicks of lever travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Parking Brake Adjustment 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Loosen or ti...

Page 89: ...5 mm of free play 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized Polaris dealer Cylinder Head Cylinder Base Fastener Torque Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours Rear Spring Adjustment The rear shock absorber sp...

Page 90: ...t belt is adjustable and should be adjusted for both the operator and passenger before driving Although having the belt at 30 is typical for many people it will not accommodate all body sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 1 2 Reposition both the buckle and retractor Tighten the bolts NOTE The center bel...

Page 91: ...ling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Locat...

Page 92: ...arking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the frame 4 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 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 tow...

Page 93: ...g normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Open the hood 2 Unplug the headlamp from the wiring harness 1 Be sure to pull on the connector not on the wiring 3 Turn the lamp counterclockwise to remove it 4 Install the new lamp ...

Page 94: ...t intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 Adjust the beam to the desired position by turning the adjustment screw 1 Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition swit...

Page 95: ...th a needle nose plier and remove the light from the assembly 6 Install the new light and use a small flat head screwdriver to seat it into place 1 4 turn clockwise 7 Snap the assembly back into the console panel and reconnect the harness 8 Close the hood Tool Kit To help you perform routine maintenance a tool kit is provided with your vehicle Items included in the kit are S A screwdriver S An ope...

Page 96: ...wer parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your Polaris dealer for free replacement If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes headlights and warning labels Many expensive repair bills can result f...

Page 97: ...Store it in a cool dry place out of the sun 4 Lubricate suspension pivot points lower steering post and rear axle fittings 5 Drain the engine side cover RANGER 4X4 6X6 6 Block the vehicle so all tires are suspended off the ground 7 Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes 8 Lubricate all cables 9 Tie a plastic bag over the exha...

Page 98: ...spark plug is tight 3 Fill the fuel tank with fuel 4 Check all the points listed in the Daily Pre Ride Inspection section on page 35 NOTE Tightness of the bolts nuts and other fasteners should be checked by an authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 54 WARNING Engine exhaust contains poisonous carbon monoxide and can cause...

Page 99: ... or tap water into the battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention...

Page 100: ...losion 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 Battery Removal 1 Open the hood 2 Remove the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of th...

Page 101: ...d tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use 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 Battery Storage When the vehicle is plac...

Page 102: ...e Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt 2872073 Chain Lube 6 25 oz aerosol 2872348 Chain Lub...

Page 103: ...nd Clearance 7 2 in 183 mm Dry Weight 1050 lbs 476 kg Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Min Turning Radius 132 in 335 3 cm Engine Oil Capacity 1 64 qts 1 55 l Coolant Capacity NA Engine 2 valve 4 stroke twin cylinder Displacement 653 cc Bore x Stroke 2 80 x 65 Pilot Jet 50 Main Jet 140 Needle Jet NA Jet Needle NA Air Screw 2 0 Alternator Output 360 W Compression Ratio 8 3 S...

Page 104: ...ront NA Drive Ratio Final 3 70 1 Tire Size Front 25 x 10 12 Tire Size Rear 25 x 11 12 Tire Pressure Front 10 psi Tire Pressure Rear 10 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Parking Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for jetting...

Page 105: ...ght 1185 lbs 537 kg 4X4 1205 lbs 547 kg NBU Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Min Turning Radius 132 in 335 3 cm Engine Oil Capacity 2 qts 2 1 l Coolant Capacity 2 25 qts 2 4 l Engine 4 valve 4 stroke single cylinder with counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42 5 Main Jet 135 Needle Jet P 6 829 Jet Needle 4MB32 3 Air Screw 2 1 2 Alternator Out...

Page 106: ...Drive Ratio Final 3 70 1 Tire Size Front 25 x 10 12 4X4 25 x 8 12 NBU Tire Size Rear 25 x 11 12 Tire Pressure Front 10 psi Tire Pressure Rear 10 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Parking Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer f...

Page 107: ...ight 1410 lbs 640 kg Cargo Box L x W x H 58 x 48 x 10 in 147 x 122 x 25 4 cm Min Turning Radius 186 in 472 4 cm Engine Oil Capacity 2 qts 2 1 l Coolant Capacity 2 25 qts 2 4 l Engine 4 valve 4 stroke single cylinder with counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42 5 Main Jet 135 Needle Jet P 6 829 Jet Needle 4MB32 3 Air Screw 2 1 2 Alternator Output 250 W Compression Rat...

Page 108: ... Ratio Final 3 70 1 Tire Size Front 25 x 10 12 Tire Size Rear 25 x 11 12 Tire Pressure Front 10 psi Tire Pressure Rear 10 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Parking Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for jetting and clutchin...

Page 109: ...s present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s replace if necessary Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Lo...

Page 110: ... plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your Polaris ...

Page 111: ...ce spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your Polaris dealer O...

Page 112: ...hat are not caused by a defect in ma terial or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit o...

Page 113: ... of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the approp...

Page 114: ...rized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before...

Page 115: ...is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities S As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Own er s Manual POLARIS recommends that you retain all receipts covering mainten ance on your LSI engine but POLARIS cannot deny warranty solely for t...

Page 116: ...arranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and interna...

Page 117: ...ilure to use recommended fuel as specified in the 2005 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and maintenance services performed at the intervals specified in the 2005 and later Owner s Manual and to reta...

Page 118: ...hange at one month J E Throttle Cable ETC Switch 50 H 6 M Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M Inspect ducts for proper sealing air leaks E Engine oil change 100 H 6 M Perform a break in oil change at 25 hours one month E Oil filter change 100 H 6 M Replace with oil change ...

Page 119: ...nt parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emission related part is found to be defective during the warranty period you must notify the Polaris...

Page 120: ...l 42 Driving in Reverse 45 Driving on Slippery Surfaces 40 Driving Over Obstacles 44 Driving Procedures 39 Driving Safely 39 50 Driving Through Water 43 Driving Uphill 41 Dumping the Cargo Box 48 E Electromagnetic Interference 53 EMISSION CONTROL SYSTEMS 52 53 Engine Idle RPM Adjustment 83 Engine Oil 60 65 Equipment Modifications 12 Exhaust Emission Control System 52 F FEATURES AND CONTROLS 25 33 ...

Page 121: ...rage 95 S SAFETY 7 24 Seat Belts 29 87 Seat Removal 29 Sidehilling 42 Spark Arrestor 53 80 Spark Arrestor 81 Spark Plug Removal 74 S Spark Plugs 74 SPECIFICATIONS 100 105 Starting a Cold Engine 36 Starting a Warm Engine 37 Starting the Engine 36 37 Steering Wheel Inspection 86 Stopping the Engine 37 Storage 94 Suspension Adjustment 38 Switches 32 T TABLE OF CONTENTS 5 Throttle Cable Adjustment 83 ...

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Polaris 2005 Ranger 4x4, Owner'S Manual For Maintenance And Safety

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