Polaris 2014 RANGER 6X6 Owner'S Manual Download | Manualshive

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79

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See
page 24.

Brake Fluid

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

WARNING!

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

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

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

1. Position the vehicle on a level surface.

2. View the brake fluid level at the reservoir in the driver’s

side wheel well.

3. The level should be between the upper (MAX) and

lower (MIN) level lines.

4. If the fluid level is lower than the upper level line, add

brake fluid to the upper (MAX) line.

5. Apply the brake forcefully for a few seconds and check

for fluid leakage around the fittings.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy

feel.

3. Check the friction pads for wear, damage and looseness.

4. Check brake discs for signs of cracks, excessive

corrosion, warping or other damage. Clean any grease
using an approved brake cleaner or alcohol.

WARNING!

Do not apply WD-40 or any petroleum product to

brake discs. These types of products are flammable and may also
reduce the friction between the brake pad and caliper.

5. Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when

worn to 3/64" (1 mm).

Park Brake Inspection

1. Apply the brakes.

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

3. Check the vehicle for movement. The vehicle should

not roll while parked. If the vehicle moves, adjust the
park brake.

Maximum

Minimum

3/64" (1mm)

Park Brake Release

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Summary of Contents for 2014 RANGER 6X6

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RANGER 800 EFI RANGER 800 EPS RANGER CREW 800 EFI RANGER 6X6 ...

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: ...y and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced 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 i...

Page 4: ...tual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other lan...

Page 5: ...Introduction 4 Safety 8 Features and Controls 21 Operation 34 Winch Guide 49 Emission Control Systems 58 Maintenance 59 Specifications 94 POLARIS Products 100 Troubleshooting 101 Warranty 104 Maintenance Log 109 Index 110 ...

Page 6: ...tential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation tha...

Page 7: ...afety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor ...

Page 8: ...our existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ________________________________________________________________________ Frame VIN _________________________________________________________________________________ Engine Serial Number ________________________________________________________________________ Key Number _________________________________...

Page 9: ... condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmen...

Page 10: ... a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will...

Page 11: ... and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at l...

Page 12: ...low careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 3 occupants 7179979 Proper Use Warning CREW Require Proper Use of Your Vehicle ...

Page 13: ...lls rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason LOCATE AND R...

Page 14: ... STEP Moving parts hazard 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 7172563 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle 7172674 RANGER 4 x 4 6...

Page 15: ... over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce roll...

Page 16: ...is manual for traveling downhill and for braking on hills See page 41 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles s...

Page 17: ...soline is extremely flammable See page 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory ...

Page 18: ... on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reactio...

Page 19: ...e Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications...

Page 20: ...maged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at ...

Page 21: ...mps or other stunts Avoid exhibition driving Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s manual See page 41 Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as desc...

Page 22: ...icle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over y...

Page 23: ...s are only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section on page 94 Headlights Front Bumper Brush Guard Radiator ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Cab Net Net Rod Mount Net Rod 6X6 Storage Box Storage Compartment Tailgate Latch Release Receiver Hitch CV Boot Rear Caliper Muffler Spar...

Page 24: ...o a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any sh...

Page 25: ...fferential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock 2WD Differential Unlock Press the top of the rocker switch to engage All Wheel Drive AWD See page 47 for operating instructions Move the rocker switch to the center position to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential an...

Page 26: ...and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 min...

Page 27: ... moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension See page 80 Always apply the service brakes before engaging or releasing the park brake 1 Apply the brakes 2 Pull the park brake lever downward as far as...

Page 28: ...traps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Please see 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 mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front fra...

Page 29: ... hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten 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 Th...

Page 30: ...tlined 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 and on CREW models under the left rear seat On 6X6 models a lockable storage box is located behind the ROPS Always make sure the cover is sec...

Page 31: ...emains and the system will automatically reduce engine power EPS Warning This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the...

Page 32: ...flash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer 3 Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It ma...

Page 33: ...splay option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance t...

Page 34: ... 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 Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to...

Page 35: ...ates retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold t...

Page 36: ...ed 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 and areas outlined on the daily pre ride inspection checklist See page 35 During the break i...

Page 37: ...ure 81 Wheels fasteners Inspect ensure fastener tightness 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 30 63 Coolant level Ensure proper level 73 Coolant hoses Inspect for leaks Throttle Ensure proper operation 78 Indicator lights switches Ensure operation 23 Air filter pre filter Inspect clean 76 Air box sediment tube Drain deposits whenever visible 76 ...

Page 38: ...7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Engage the park brake WARNING...

Page 39: ...gine and allow it to warm up 6 Apply the service brakes and shift the transmission into gear 7 Check your surroundings and determine your path of travel 8 Release the park brake 9 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 10 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 1...

Page 40: ...rs secure their seat belt 5 Make sure all cab nets or doors are properly secured 6 Do not carry more than the recommended number of passengers for your vehicle See page 10 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause disc...

Page 41: ...g 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 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...

Page 42: ...ds such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle tha...

Page 43: ... could be on the 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 rollover 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 Driving Downhill W...

Page 44: ...t before entering 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 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 ...

Page 45: ...Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Turn the engine off 4 Engage the park brake 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if...

Page 46: ...andling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loa...

Page 47: ...not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 94 6 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 7 Never tow a trailer on a grade steeper than 15 Belt Life To extend belt life use the lowest gear possible when hauli...

Page 48: ...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 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 7 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo box ...

Page 49: ...ng to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In so...

Page 50: ... or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive On 6X6 models all four rear wheels will be drive wheels Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggre...

Page 51: ...le winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and mov...

Page 52: ...run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable bef...

Page 53: ...g strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 54: ...arts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kil...

Page 55: ...e moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 56 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the...

Page 56: ... is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook...

Page 57: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 58: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and poss...

Page 59: ...ctivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be ...

Page 60: ...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 performance and are not ...

Page 61: ...inition 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 contaminants collecting in the oil sump or crankcase Change oil immediately if the ...

Page 62: ...ped Daily Inspect daily clean often Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Ź E Air filter main element Weekly Inspect replace as needed Ź D Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test Ź E Engine breather filter if equipped 25 H Monthly Inspect replace if necessary Ź Engine oil change break in 25 H 1 M Perfo...

Page 63: ...hange fluid Ź Middle Gearcase oil if equipped 100 H 12 M Change fluid Ź Rear gearcase oil if equipped 100 H 12 M Change fluid Ź Transmission oil 100 H 12 M Change fluid D E Fuel system 100 H 12 M Check for leaks at tank cap lines fuel valve filter pump throttle body replace lines every two years Ź Radiator if applicable 100 H 12 M Inspect clean external surfaces Ź Cooling Hoses if applicable 100 H...

Page 64: ...dd to proper level on dipstick See page 63 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 79 Main Gearcase Oil Transmission AGL Gearcase Lubricant Transmission Fluid See page 67 6X6 See page 66 4X4 CREW Front Gearcase Oil Demand Drive Fluid See page 68 Middle Gearcase Oil 6X6 ATV Angle Drive Fluid See page 69 Rear Gearcase Oil 6X6 ATV Angle Drive Fluid See page 70 Prop Sh...

Page 65: ...on recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always use the recommended engine oil Oil Check The oil dipstick and fill tube is located on the engine 1 Position the vehicle on a level surface 2 Remove the seat and th...

Page 66: ... the seat and the underseat storage box 10 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 11 Using a clean dry cloth clean the filter sealing surface on the crankcase 12 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 13 Install the new filter and turn by ha...

Page 67: ...Transmission AGL Gearcase Lubricant Transmission Fluid 43 6 oz 1290 ml 12 ft lbs 16 3 Nm 12 ft lbs 16 3 Nm Front Gearcase Demand Drive Fluid 9 3 oz 275 ml 8 10 ft lbs 11 13 6 Nm 11 ft lbs 15 Nm Middle Gearcase ATV Angle Drive Fluid 6 75 oz 200 ml 14 ft lbs 19 4 Nm 14 ft lbs 19 4 Nm Rear Gearcase ATV Angle Drive Fluid 18 oz 532 ml 14 ft lbs 19 4 Nm 14 ft lbs 19 4 Nm RANGER CREW Gearcase Specificati...

Page 68: ... of the level check fill plug hole threads 1 Position the vehicle on a level surface 2 Remove 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...

Page 69: ...urface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change The drain plug 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 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Wipe t...

Page 70: ...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 hand...

Page 71: ...POLARIS products The middle gearcase fill plug is located on the side of the gearcase Oil Check 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 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely ...

Page 72: ...ear gearcase Oil Check Maintain the oil level even with the bottom thread of the fill plug hole 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 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely ...

Page 73: ... spark plug cap 2 Using the 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 an...

Page 74: ...mmends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 100 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the coo...

Page 75: ...ten or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Coolant Level 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant le...

Page 76: ...the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer 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...

Page 77: ...h components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to...

Page 78: ...ehicle to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 75 for drying Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Service the air filter more frequently if the vehicle is operated in wet conditions...

Page 79: ...while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plugs located on the bottom of the muffler 2 Place the transmission in neutral 3 Engage the park brake 4 Start the engine 5 Purge accumulated carbon from the system by momentarily revving the engine several times 6 If carbon is expelled cover or plug the ex...

Page 80: ...the Periodic Maintenance Chart beginning on page 59 Adjust the freeplay if necessary 1 Apply the brakes Engage the park brake Shift the transmission to neutral 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 ma...

Page 81: ...d be between the upper MAX and lower MIN level lines 4 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear dam...

Page 82: ...e cable as needed 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 59 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay 3 If there is excessive freeplay or strange noises or the steering feels ...

Page 83: ...f tires for this vehicle 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 maintenance 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 ...

Page 84: ...side 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 dealer 5 Attach the wheel nuts and washers and finger tighten 6 Caref...

Page 85: ...mp 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 harness 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 ...

Page 86: ...e same height 4 Apply the brakes Start the engine Turn on the headlights 5 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step 6 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 7 Loosen the screw adjust the headlig...

Page 87: ...re fuses are provided in the fuse box The power steering fuse if equipped is located on the power steering wiring harness near the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Feature Supported 20A Accessories 12V Power Receptacle 10A Electronic Fuel Injection 20A Engine Control Module 20A Lights 20A Main Fuse Ignition Instrument Clus...

Page 88: ... a conventional battery A sealed battery can be identified by its flat covers on the top of the battery 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 wate...

Page 89: ... last 1 Remove the seat Remove the storage bin 2 Remove the screws from the battery hold down strap and remove the strap 3 Disconnect the black battery cable first 4 Disconnect the red battery cable last 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 solution of on...

Page 90: ...cables are properly routed and install the hold down strap Tighten the screws securely Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 89 POL...

Page 91: ...ge 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 2 If the voltag...

Page 92: ... 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 lab...

Page 93: ...RIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Cha...

Page 94: ... add 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 71 ...

Page 95: ...lined in the Periodic Maintenance Chart beginning on page 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes Engage the park brake 2 Stop the engine 3 Place the transmission in gear 4 Secure the fuel cap oil cap hood and seat Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while ...

Page 96: ...l Length 114 in 289 6 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 76 in 193 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Ground Clearance 11 5 in 29 2 cm Min Turning Radius 158 in 401 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 ...

Page 97: ...e 7 00 1 Gear Reduction High 3 6 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 105 1 Tire Size Front 25 x 10 12 26 x 9 12 for select models Tire Size Rear 25 x 11 12 26 x 11 12 for select models Tire Pressure Front 10 psi 69 KPa Tire Pressure Rear 12 psi 83 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechanical Hood Headlight 2 single beam 50W quartz halo...

Page 98: ... 3 cm Overall Height 76 in 193 cm Wheelbase 105 in 267 cm Cargo Box Dimensions Inside 42 5 x 54 x 11 5 in 108 x 137 x 29 cm Ground Clearance 12 in 30 5 cm Min Turning Radius 243 in 617 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting System Electric Fuel System Electronic Fue...

Page 99: ... 91 1 Gear Reduction High 3 85 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 70 1 Tire Size Front 25 x 10 12 Tire Size Center Rear 25 x 11 12 Tire Pressure Front 10 psi 69 kPa Tire Pressure Center Rear 12 psi 83 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechanical Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L ...

Page 100: ...ox 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 108 in 274 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 255 in 648 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Start...

Page 101: ... 70 1 Gear Reduction Reverse 7 0 1 Gear Reduction High 4 63 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 105 1 Tire Size Front 26 x 9 12 Tire Size Rear 26 x 11 12 Tire Pressure Front 12 psi 83 KPa Tire Pressure Rear 14 psi 97 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechanical Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Br...

Page 102: ...al 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 l 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2...

Page 103: ... to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over 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 roll ov...

Page 104: ...ld or non recommended fuel Replace with fresh recommended fuel Fouled or defective 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 In...

Page 105: ...ion 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 Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wir...

Page 106: ... the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVE...

Page 107: ...ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY...

Page 108: ...ur vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notice...

Page 109: ...arranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers com...

Page 110: ... warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS ...

Page 111: ...109 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 112: ...ent Locations 21 Console 22 Coolant Level Overflow Bottle Coolant 73 Coolant Level Radiator 73 Coolant Adding or Changing 72 Cooling Fan 72 Cooling System 72 73 Crankcase Emission Control System 58 D Differential Lock Switch 23 Differential Locking 48 Disengaging AWD 47 Display Units Standard Metric 31 Drive Belt Wear 101 Drivetrain Break In 34 Driving Downhill 41 Driving in Reverse 43 Driving on ...

Page 113: ...es 9 H Hauling Cargo 44 Headlight Beam Adjustment 84 Headlight Lamp Replacement 83 Helmet 8 Hitch 24 Hitch Weight 45 I Idle Speed 78 Ignition Switch 23 Indicator Lamps 29 Inspection Pre Ride 35 Instrument Cluster 29 33 Intake Restrictor Plate 63 Interference Electromagnetic 58 K Key Periodic Maintenance Chart 59 L Lamp Replacement Headlight 83 Light Switch 23 Lights 83 84 Load Capacity 44 Lubricat...

Page 114: ...ng Gear 8 9 Rollover Protective Structure 28 ROPS Cab Frame 28 S Safety Labels 10 12 Safety Symbols 4 Safety Winch Maintenance 57 Seat Belts 27 Seat Removal 27 Severe Use Definition 59 Shifter 22 Shifting Gears 22 Shock Loading the Winch 56 Shock Spring Adjustment 80 Signal Words 4 Spark Arrester Warning 77 Spark Plug Gap 71 Spark Plug Inspection 71 Spark Plug Recommendations 71 Spark Plug Torque ...

Page 115: ...nsmission Operation 74 75 Transmission System 74 75 Transmission Warning 74 75 Transmission Drying 75 Transporting the Vehicle 93 Tread Depth 81 V Vehicle Identification Numbers 6 Vehicle Immersion 76 Vehicle Transport 93 W Warning Symbols 4 Warning Transmission Modification 74 75 Washing the Vehicle 90 Water Immersion of Vehicle 76 Wheel Installation 82 Wheel Nut Inspection 81 Wheel Nut Torque 81...

Page 116: ...ear your seat belt Vehicle rollover can cause severe injury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passengers read and understand all safety labels Operate slowly in reverse avoid sharp turns or sudden braking On paved surfaces pavement may seriously affect handling and control With non Polaris approve...

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