Polaris 2010 Ranger 400 HO Owner'S Manual Download Page 84

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MAINTENANCE

Suspension Adjustments

The front and rear suspensions can be adjusted to provide a stiffer sus-

pension, if necessary.
1. Remove the top shock mounting bolts from the inside mounting

holes.

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

Spring Adjustment

Adjust the front and rear shock absorber springs by rotating the adjust-

ment cam either clockwise or counter-clockwise to increase or decrease

spring tension.

Cam

Rear Suspension Shown

Adjustment is similar for Front Suspension

Summary of Contents for 2010 Ranger 400 HO

Page 1: ......

Page 2: ...elve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stabi...

Page 3: ...ns in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to th...

Page 4: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 5: ...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 abou...

Page 6: ...nd quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication...

Page 7: ...tion 4 Safety 7 Features and Controls 18 Operation 27 Emission Control Systems 47 Maintenance 48 Specifications 98 Polaris Products 100 Troubleshooting 101 Declaration of Conformity 105 Warranty 106 M...

Page 8: ...ading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTI...

Page 9: ...ail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle...

Page 10: ...sing your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Fra...

Page 11: ...n cause serious injury or death Never carry passengers in cargo box Maximum Box Load 500 lbs 227 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH...

Page 12: ...t 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 7176170 Clutch Cover Warning WARNING Moving part...

Page 13: ...pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or d...

Page 14: ...ver and any passenger must wear helmet eye protection and seat belt at all times Always keep arms and legs inside the cab frame while the vehicle is in motion Always keep both hands on the steering wh...

Page 15: ...ures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle...

Page 16: ...d on safety labels Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securel...

Page 17: ...substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made...

Page 18: ...ating 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 terra...

Page 19: ...k If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engin...

Page 20: ...r overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps...

Page 21: ...speed Improper Tire Maintenance 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 speci...

Page 22: ...18 FEATURES AND CONTROLS Component Locations ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Headlights Front Bumper Brush Guard Radiator...

Page 23: ...eceiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on page...

Page 24: ...used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Indicator Lights Indicator Lights Cup Holder Storage Compartment 12V Aux...

Page 25: ...two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or whe...

Page 26: ...e vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustme...

Page 27: ...le Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest posi tion when released Always check that the throttle pedal returns nor mally before starting the e...

Page 28: ...result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat...

Page 29: ...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 stiffn...

Page 30: ...cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Seat Removal Pull up on the front of the seat and slide it toward the front of the vehi cle Instal...

Page 31: ...ty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will...

Page 32: ...sitions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 29 6 Pull only light loads 7 During th...

Page 33: ...ry 53 Steering Ensure free operation 79 Tires Inspect condition and pressure 7 81 Wheels fasteners Inspect ensure fastener tightness 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil...

Page 34: ...e spark plugs to become wet fouled 6 If the engine is cold pull the choke knob out until it stops 7 Turn the ignition key to START Engage the starter for a maxi mum of five seconds Release the key whe...

Page 35: ...gine idles smoothly 12 Push the choke knob in NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the veh...

Page 36: ...d determine your path of travel 6 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 7 Drive slowly Practice maneuvering...

Page 37: ...weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and...

Page 38: ...4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Proceed at a steady rate of speed and throttle opening Never open the...

Page 39: ...ble follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions 1 Avoid steep h...

Page 40: ...ntering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on y...

Page 41: ...lways check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use...

Page 42: ...erse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly fo...

Page 43: ...n 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 Turn the engine off 4 Block the rear wheels on the...

Page 44: ...oads 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 OP...

Page 45: ...cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities WARNING Driving with passengers in the cargo box can result in severe injury...

Page 46: ...the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 7 Stand clear and pull up on the cargo box release lever 8 Lift...

Page 47: ...mmended weight for the vehicle See the towing capacity chart below and the specifications charts begin ning on page 98 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to a...

Page 48: ...nside 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...

Page 49: ...eeded 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 swit...

Page 50: ...ore engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and oper...

Page 51: ...ss 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...

Page 52: ...vice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of ap...

Page 53: ...ed service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing th...

Page 54: ...ers Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X E Air box sediment tube Daily Drain deposits when visible Cool...

Page 55: ...50 H 6 M Inspect lubricate adjust Q Steering 50H 6 M Lubricate X Front Suspension 50 H 6 M Lubricate X Rear Suspension 50 H 6 M Lubricate Carburetor float bowl 50 H 6 M Drain bowl periodically and pri...

Page 56: ...Hoses 100 H 12 M Inspect for leaks X Engine mounts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect X E Spark plug 100 H 12 M Inspect replace as needed Q E Ignition timing 100 H 12 M Inspect...

Page 57: ...ted in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 See page 55 Brake Fluid DOT 4 See page 78 Main Gearcase Oil...

Page 58: ...aintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for th...

Page 59: ...tion the vehicle on a level surface Place the transmission in PARK 2 Start the engine and allow it to idle for 20 30 sec onds Stop the engine 3 Remove the seat See page 26 4 Remove the dipstick Wipe i...

Page 60: ...in completely 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to...

Page 61: ...additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case Tip The sealing surfaces on the drain p...

Page 62: ...ely 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If...

Page 63: ...tions See page 100 for the part numbers of Polaris products Oil Check The fill plug is located at the rear of the vehicle 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the o...

Page 64: ...specifications 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Drain the oil 4 Wipe the magnetic end of the drain plug clean to remove accumu lated metallic fi...

Page 65: ...n the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to spec...

Page 66: ...ndition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 62 CAUTION A hot exhaust system and engine c...

Page 67: ...tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjust ments Wet Fouled Plug The wet fouled insulator tip is black...

Page 68: ...creases 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 d...

Page 69: ...the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator shou...

Page 70: ...nt of the right front wheel 1 Position the vehicle on a level surface 2 View the coolant level in the overflow bottle 3 If the coolant level is below the safe operating range lift the hood and locate...

Page 71: ...TION 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 cap 3 Vi...

Page 72: ...have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is inte...

Page 73: ...stall 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 wi...

Page 74: ...carburetor drain screw two turns 5 Dry any water present in the air box Filter replacement is required if water is present 6 Thoroughly dry the air pre cleaner located under the hood 7 Turn the engine...

Page 75: ...spect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 4 Do not attempt to clean the main element Install a new air filter Tip Apply a small amount...

Page 76: ...for debris Blow gently through the filter in the direction of the arrow to check for clog ging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall...

Page 77: ...nt If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted 1 Apply the brakes 2 Place the transmission in PARK 3 Start the engine and allow it...

Page 78: ...peratures 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...

Page 79: ...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...

Page 80: ...throttle pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle...

Page 81: ...n the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 76 Tip While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the...

Page 82: ...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...

Page 83: ...to 3 64 1 mm Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 1 Position...

Page 84: ...ide mounting holes 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft lbs 40 Nm Spring Adjustment Adjust the front and rear shock absorber sprin...

Page 85: ...iginal equipment size and type when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following it...

Page 86: ...osition on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can adversely affect tire wear...

Page 87: ...fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow l...

Page 88: ...tart 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 o...

Page 89: ...ch in behind the console panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembly...

Page 90: ...ery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top o...

Page 91: ...e negative black cable last 1 Remove the seat 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first 4 Disconnect the red battery cable last 5 Lift the bat...

Page 92: ...te it down in front of the shift cable into the left front wheel well 4 Route the vent tube through the hole in the frame support from the back side and place it behind the wheel well panel NOTICE Rou...

Page 93: ...Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery...

Page 94: ...the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing...

Page 95: ...dard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months...

Page 96: ...cts 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...

Page 97: ...olaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evapora...

Page 98: ...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 periodical...

Page 99: ...arbon 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 stabilize...

Page 100: ...the inside of the spark plug cap Reinstall the cap 4 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film o...

Page 101: ...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 48 Transport...

Page 102: ...learance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacity 1250 lbs 567 kg Max Cargo Box Load 500 lbs 227 kg Engine 4 valve 4 stroke single cylinder with counter balance Lubrication Syste...

Page 103: ...r Reduction Reverse 7 00 1 Gear Reduction High 4 12 1 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 68 9 kPa Tire Pressure Rear 10 psi 68 9 k...

Page 104: ...z 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium...

Page 105: ...mission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from...

Page 106: ...gs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace s...

Page 107: ...Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or p...

Page 108: ...n and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections...

Page 109: ...009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH...

Page 110: ...hine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any fai...

Page 111: ...as been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that...

Page 112: ...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 r...

Page 113: ...ized 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 wi...

Page 114: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 115: ...ue 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 compet...

Page 116: ...112 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 117: ...113 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 118: ...114 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

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