Polaris 2013 RANGER 500 Midsize Owners Manual/Install Manual Download | Manualshive

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MAINTENANCE

Fuses

If the engine stops or will not start, or if you experi-
ence other electrical failures, a fuse may need
replacement. Locate and correct any short circuits
that may have caused the blown fuse, then replace
the fuse. Spare fuses are provided in the fuse box.

If you suspect that a fuse or relay may not be work-
ing properly, please see your POLARIS dealer.

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses
become dirty during normal operation. Clean lights frequently and replace burned out lamps
promptly. Always make sure lights are adjusted properly for best visibility.

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

Headlight Lamp Replacement

1. Open the hood.

CAUTION!

Hot components can cause burns to skin.

Allow lamps to cool before servicing.

2. Unplug the headlamp from the wiring har-

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

3. Turn the lamp counterclockwise to remove

it.

4. Install the new lamp.

Tip:

Make sure the tab on the lamp locates properly in
the housing.

5. Reinstall the harness assembly into the head-

light assembly.

Fuse

Feature Supported

10A

Accessories, 12V Power Receptacle

10A

Headlight

10A

Taillight

20A

Chassis

Wiring Harness

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Summary of Contents for 2013 RANGER 500 Midsize

Page 1: ...RANGER 500 Midsize RANGER CREW 500 Owner s Manual for Maintenance and Safety ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...per vehicle use can result in SEVERE INJURY or DEATH READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923950 Rev 02 Printed in USA NEVER Operate ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a...

Page 5: ...he engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed on...

Page 6: ...een the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabil ity can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in Englis...

Page 7: ... CONTENTS Introduction 4 Safety 6 Features and Controls 17 Operation 30 Emission Control Systems 42 Maintenance 43 Specifications 74 POLARIS Products 76 Troubleshooting 77 Warranty 80 Maintenance Log 85 Index 87 ...

Page 8: ...NEEDS to be taken to avoid a hazard Failure to follow the warnings contained in this manual can result in severe injury or death A POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if y...

Page 9: ..._____________________ Key Number _______________________________________________________________________________ European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated ...

Page 10: ...d under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7175488 Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if ...

Page 11: ...es or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176169 Discretionary Warning Crew 500 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees 15 On public roads a collision can occur wit...

Page 12: ...eful if load extends over the side of the box Read Owner s Manual for more detailed loading information 7177073 Passenger Tire Pressure Warning Crew 500 WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box WARNING Maximum Box Load 500 lbs 227 kg WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJ...

Page 13: ...he country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V ...

Page 14: ...both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consu...

Page 15: ...skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it...

Page 16: ...a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics ...

Page 17: ...ifferent situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while ...

Page 18: ...ear the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your...

Page 19: ...vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel r...

Page 20: ...ra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Neve...

Page 21: ...ustrated below is shown without cab nets only to allow component identification Always use the cab nets Not all models come with all features Refer to the specifications section beginning on page 74 ROPSCab Frame Console Hip Bar Cargo Box Fuel Tank Cap Headlights Front Bumper Brush Guard Radiator Cab Net Tailgate Latch Releases Receiver Hitch CV Boot Rear Caliper Muffler Spark Arrester Tailgate ...

Page 22: ...ssion in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is mov ing Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems NOTICE Shifting gears with the engine speed above i...

Page 23: ... and operate in two wheel drive 2WD See page 40 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed OFF The engine is off Electrical circuits are off except Acc 12V LIGHTS ON Lights are on Electri...

Page 24: ... the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay See page 59 for throttle pedal adjustment procedures Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use ...

Page 25: ...it will self tighten Tip The center belt must be tightened manually by pulling on the strap 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s...

Page 26: ...y replace worn or damaged cab nets with new cab nets available from your authorized Polaris dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properly secured in the slot at the base of the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Openin...

Page 27: ...mes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Storage Compartments A storage compartment is located under the driver s seat on CR...

Page 28: ...luster measures distance traveled by the vehicle as well as time hours of opera tion and engine RPM Tip In addition to showing vehicle speed the speedometer needle flashes when a low fuel condi tion exists Rider Information Center Speedometer Speedometer Needle ...

Page 29: ...nostic Mode Indi cator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The ...

Page 30: ...isplays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnos tic mode tu...

Page 31: ...onds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about seven 7 seconds until either ON or OFF appears in the ...

Page 32: ...e has been set Accessing Blink Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 29 for Blink Codes and Failure Descriptions Use the following procedure to access blink codes failure codes from the EFI module 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Turn the key switch to the ON position 5 T...

Page 33: ...Circuit to Battery 53 Rear Differential Open Load RANGER 4X4 only 53 Rear Differential Short Circuit to Ground RANGER 4X4 only 53 Rear Differential Short Circuit to Battery RANGER 4X4 only 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Ba...

Page 34: ...ine Heed the gasoline warnings on page 14 2 Check the oil level See page 46 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls...

Page 35: ...eration 61 Tires Inspect condition and pressure 8 62 Wheels fasteners Inspect ensure fastener tightness 62 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 20 46 Coolant level Ensure proper level 53 Coolant hoses Inspect for leaks Throttle Ensure proper operation 59 Indicator lights switches Ensure operation 19 Air filter pre filter Inspect clean 57 Air box sed...

Page 36: ...y with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Place the transmission in PARK WARNING A rolling vehicle c...

Page 37: ...See page 31 2 Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold 3 Make sure all passengers are wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 4 Make sure all passengers secure their seat belt 5 Make sure all ...

Page 38: ...the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid...

Page 39: ...he other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When...

Page 40: ...entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obsta cles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RAN...

Page 41: ... Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an...

Page 42: ... and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adv...

Page 43: ... evenly or toward the front of the cargo box 5 Release the tailgate latches WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 Stan...

Page 44: ...e in two wheel drive 2WD Locking the differen tial in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Differential Unlocked Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD When the rear differential is unlocked the rear wheels can rota...

Page 45: ...isengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AW...

Page 46: ...quipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal per formance and are not...

Page 47: ...se must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate con taminants colle...

Page 48: ...lace as needed D Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test E Engine breather filter if equipped 25 H Monthly Inspect replace if necessary Front Gearcase oil if equipped 25 H 1 M Perform a break in oil level check Middle Gearcase oil if equipped 25 H 1 M Perform a break in oil level check Rear gearcase oil if equipped 25 H 1 M Perform a break i...

Page 49: ...pplicable 100 H 12 M Inspect clean external surfaces Cooling Hoses 100 H 12 M Inspect for leaks Engine mounts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect E Spark plug 100 H 12 M Inspect replace as needed D Ignition timing 100 H 12 M Inspect Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors sub jected to water mud etc D Clutches drive and drive...

Page 50: ...mbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface Place the transmission in PARK 2 Start the engine and allow it to idle for 20 30 seconds Stop the engine 3 Remove the seat See page 2...

Page 51: ...l to drain 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 14 ft lbs 19 Nm 9 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting Tip The fitting threads must be sealed with LOCTITE PST 505 or PTFE ...

Page 52: ... 17 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 18 Remove the dipstick and fill the tank with two quarts 1 9 l of the recommended oil 19 Prime the oil pump using the procedure on page 48 Then stop the engine and inspect for leaks 20 Check the oil level on the dipstick Add oil as necessary to bring the level to the upper mark on the dipstick 21 Dispose of used filter and oil properly Oil Pum...

Page 53: ...the level check fill plug Check the oil level 3 Remove the rear fill plug and add the recommended oil as needed 4 Reinstall both fill plugs Torque to specification Oil Change The drain plug is located near the bottom of the gearcase 1 Remove the rear fill plug and the level check fill plug 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to drain completely 4 Clean and ...

Page 54: ... on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right ...

Page 55: ... spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 3 Reverse the procedure for spark plug installation Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip shoul...

Page 56: ...s the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 76 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time ...

Page 57: ...d radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Do not obstruct or deflect air flow through the radiator by installing unauthorized accesso ries in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to over heating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns N...

Page 58: ...ined 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 Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when repla...

Page 59: ... completely Reinstall the drain plug 3 Place the transmission in PARK 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 7 Test for belt slippage If the bel...

Page 60: ...if water is present 3 Thoroughly dry the air pre cleaner located under the hood 4 Remove the spark plugs Turn the engine over several times using the electric start 5 Dry the spark plugs and reinstall or replace with new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it o...

Page 61: ...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 con tainer Breather Filter and Hoses 1 Lift the cargo box and locate the air box 2 Follow the right hand breather line out the side of the air box and locate the filter 3 Remove and inspect the filter for debris Blow gen...

Page 62: ... it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe ...

Page 63: ...on page 43 Adjust the freeplay if necessary 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dea...

Page 64: ...the reservoir are unknown See page 45 for fluid recommendations 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and che...

Page 65: ...ce 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counterclockwise to increas...

Page 66: ...ize 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 items occasionally for tightness and if they ve been loosened for main tenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Aluminum Wheels Front and Rear 30 ft lbs 41 Nm PLUS 1 4...

Page 67: ...position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dea...

Page 68: ... Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring har n...

Page 69: ...e mark placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light bef...

Page 70: ...a con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap wat...

Page 71: ...k cable last 1 Remove the front seat 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Discon nect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solut...

Page 72: ... and is securely installed as recommended 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 7 Install the battery hold down strap Battery Storage Whenever the vehicle is not used for a perio...

Page 73: ...voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the vol...

Page 74: ...or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labe...

Page 75: ...rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period ...

Page 76: ...2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 51 4 App...

Page 77: ... 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 43 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Secure the fuel cap oil cap and seat 5 Always tie the fram...

Page 78: ... 10 in 25 4 cm 10 in 25 4 cm Min Turning Radius 150 in 381 cm 237 in 602 cm Towing Capacity 1250 lbs 567 kg 1250 lbs 567 kg Hitch Tongue Capacity 150 lbs 68 kg 150 lbs 68 kg Max Cargo Box Load 500 lbs 227 kg 500 lbs 227 kg Engine 4 valve 4 stroke single cylinder with counter balance Displacement 498 cc 498 cc Bore x Stroke mm 92 x 75 92 x 75 Alternator Output 350 W 350 W Compression Ratio 10 2 1 1...

Page 79: ... 12 1 Drive Ratio Front 3 818 1 3 818 1 Tire Size Front 25 x 8 12 25 x 10 12 Tire Size Rear 25 x 11 12 25 x 11 12 Tire Pressure Front 10 psi 68 9 kPa 14 psi 96 5 kPa Tire Pressure Rear 12 psi 82 7 kPa 16 psi 110 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen 2 single beam 50W quartz halogen Tailligh...

Page 80: ...ium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871...

Page 81: ...ssion to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle ov...

Page 82: ...ctive spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range...

Page 83: ...ed air filter Inspect and clean or replace Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Insp...

Page 84: ...ntal damage normal wear and tear abuse or improper handling This war ranty also does not cover any vehicle that has been altered structurally modified neglected improperly main tained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition ...

Page 85: ...consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED...

Page 86: ...warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obt...

Page 87: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited war ranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 88: ...by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or ot...

Page 89: ...85 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 90: ...86 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 91: ...Overflow Bottle 53 Coolant Level Radiator 53 Coolant Adding or Changing 52 Cooling Fan 52 Cooling System 52 53 Corrosion Removal Chrome 71 Crankcase Emission Control System 42 Cylinder Head 56 D Diagnostic Mode 26 28 Diagnostics AWD 27 Diagnostics EFI Blink Codes 29 Diagnostics Gear Circuit 27 Differential Lock Switch 19 Differential Operation 40 Disengaging AWD 41 Drive Belt Wear 77 Drivetrain Br...

Page 92: ...Shifting 18 Gloves 9 H Hauling Cargo 38 Headlight Beam Adjustment 65 Headlight Lamp Replacement 64 Helmet 9 Hitch Bracket 20 Hitch Weight 39 Hour Meter 26 I Idle Speed 59 Ignition Switch 19 Immersion of Vehicle 56 Instrument Cluster 24 29 K Key Periodic Maintenance Chart 43 Kilometers to Miles Toggle 28 L Light Switch 19 Lights 64 65 Brake Lights 65 Headlight Beam Adjustment 65 Headlight Lamp Repl...

Page 93: ...Inspection 51 Spark Plug Recommendations 51 Spark Plug Torque 51 Spark Plugs 51 Spark Plugs Fouled 51 S Specifications 74 75 Specifications Gearcase 49 Speed Towing 39 Speedometer 24 Starting the Engine 32 Steering Wheel Inspection 61 Stopping the Engine 32 Storage 70 72 Storage Area 72 Storage Compartments 23 Storage Tips 71 Storage Battery 68 Storage Covers 72 Storage Removal from 73 Switches 19...

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