Polaris Ranger 4X4 Owner'S Manual Download Page 60

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MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 50. Always change the

oil filter whenever changing oil.

WARNING!

Vehicle operation with insufficient, deteriorated, or contaminated

engine oil will cause accelerated wear and may result in engine seizure,

accident, and injury. Always perform the maintenance 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. See page 102 for the part num-

bers 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.

Summary of Contents for Ranger 4X4

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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: ...ign and 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 publica...

Page 7: ...tion Numbers 4 Safety 7 Features and Controls 18 Operation 29 Emission Control Systems 49 Maintenance 50 Specifications 100 Polaris Products 102 Troubleshooting 103 Declaration of Conformity 107 Warra...

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: ...Never carry passengers in cargo box Maximum 4X4 Box Load 1000 lbs 455 kg Maximum 6X6 Box Load 1250 lbs 567 kg Storage Box Load 250 lbs 113 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of co...

Page 12: ...ngine RPM which can result in serious injury or death 7172563 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 ve...

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: ...r use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and fol low the instructions in this manual for haul...

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: ...ng 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 terrain...

Page 19: ...ed 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 Exposure to Exhaust Engine exhaust fum...

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: ...ROLS Component Locations Not all models come with all features Refer to the specifications section beginning on page 100 ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Headlights Front Bumper...

Page 23: ...receiver 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 pag...

Page 24: ...onal accessories or lights The connections are behind the console under the hood Fuel Gauge Hour Meter Lighted bars in the upper display indicate fuel level Hours of engine operation since manufacture...

Page 25: ...ver 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 adjustment is important to assure proper transmis sion f...

Page 26: ...switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START p...

Page 27: ...Off 1WD Turf Mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 48 for AWD operating instructions Move the rocker switch to the center position to lock the differential an...

Page 28: ...he desired position Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressu...

Page 29: ...e switch has 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...

Page 30: ...perly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and...

Page 31: ...the seat belt system checked and or replaced by an authorized Polaris dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or househol...

Page 32: ...ho rized Polaris dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices...

Page 33: ...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 34: ...vels controls and areas outlined on the daily pre ride inspection checklist See page 31 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours 8 Inspect an...

Page 35: ...ires Inspect condition and pressure 7 82 Wheels fasteners Inspect ensure fastener tightness 82 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 27 57 Coolant level...

Page 36: ...RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 6 If the engine does not start within five seconds release the ignition switch and wait f...

Page 37: ...e can cause serious injury Always engage the park brake after stopping the engine Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly 3 Practice starting and s...

Page 38: ...into gear 5 Check your surroundings and determine your path of travel 6 Release the park brake 7 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your r...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...oid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in gear 3 Engage the park brake 4 Turn the engine off 5 Block the rear wh...

Page 46: ...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 47: ...s 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 injur...

Page 48: ...xpectedly 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 7 Stand clear and pull up o...

Page 49: ...ommended weight for the vehicle See the towing capacity chart below and the specifications charts begin ning on page 100 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to...

Page 50: ...ng 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...

Page 51: ...e in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Diffe...

Page 52: ...sengage 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...

Page 53: ...ns are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by...

Page 54: ...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 55: ...ected to severe use E Emission Control System Service 4 Cycle California Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could r...

Page 56: ...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 57: ...ication 50 H 3 M Lubricate all fittings pivots cables etc Shift Linkage 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...

Page 58: ...ct 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 Ignition timing 100 H 12 M Inspect X Wiring 100 H 12 M Ins...

Page 59: ...ted in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil Polaris PS 4 PLUS Performance Synthetic 2W 50 4 cycle Oil See page 57 Brake Fluid DOT 4 See page 7...

Page 60: ...e accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations Polaris recommends t...

Page 61: ...engine 3 Remove the seat See page 27 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick Screw it in completely Tip The dipstick must be screwed in completely to keep the ang...

Page 62: ...6 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 7 Reinstall the drain plug Torque to 14 ft lbs 19...

Page 63: ...e then turn and additional 1 2 turn 15 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 surface...

Page 64: ...20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Tip If you do not hear air the l...

Page 65: ...ck The fill plug is located on the side of the gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level Add the recommended oil as needed 4 Reinstall the fill pl...

Page 66: ...to the Gearcase Specifications Chart on page 60 for recommended lubricants capacities and torque specifications See page 102 for the part numbers of Polaris products Oil Check The front gearcase fill...

Page 67: ...s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Remove the drain plug Drain the oil 6 Clean the drain plug Reinstall the drain plug Torque to sp...

Page 68: ...condition 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 64 CAUTION A hot exhaust system and engine...

Page 69: ...service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator...

Page 70: ...ommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained...

Page 71: ...t recommended Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 50 Maintain the coolant level between the...

Page 72: ...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 73: ...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 74: ...akes Start the engine 4 Engage the park brake 5 Shift the transmission to neutral 6 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the thr...

Page 75: ...the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Thoroughly dry the air pre cleaner located under the hood 4 Remove the spark plugs Turn the en...

Page 76: ...ded periods 1 Lift the cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 4 Do...

Page 77: ...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 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: ...e engine several times 4 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 5 If particles are still susp...

Page 80: ...cessive 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 pedal has no freeplay...

Page 81: ...inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn 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 lig...

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: ...ar damage and looseness 4 Inspect the brake disc spline and pad wear surface for excessive wear 5 Change pads when worn to 3 64 1 mm Park Brake Inspection 1 Apply the brakes 2 Pull the park brake leve...

Page 84: ...or This will inacti vate the limiting function Reconnect the connector as soon as possible and adjust the park brake cable to proper tension 1 Position the vehicle on a level surface 2 Shift the trans...

Page 85: ...eposition 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 adj...

Page 86: ...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 87: ...ace the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels c...

Page 88: ...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 89: ...akes Start 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 r...

Page 90: ...ach 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 assembl...

Page 91: ...eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi...

Page 92: ...ct the negative black cable last 1 Open the hood 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...

Page 93: ...the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contac...

Page 94: ...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 95: ...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 96: ...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 97: ...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 working properly please see...

Page 98: ...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 99: ...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 100: ...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 101: ...mmended 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 all...

Page 102: ...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 t...

Page 103: ...f 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 50 Transporting the RAN...

Page 104: ...n 193 cm Wheelbase 76 in 193 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 12 in 30 5 cm Min Turning Radius 158 in 401 cm Towing Capacity 1500 lbs 681 kg Max Cargo Box...

Page 105: ...n Reverse 7 0 1 Gear Reduction High 4 12 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 105 1 Tire Size Front 25 x 10 12 Tire Size Rear 25 x 11 12 Tire Pressure Front 8 12 psi 69 kPa Tire Pressure Rea...

Page 106: ...mium Demand Drive Hub Fluid 8 oz 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...

Page 107: ...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 108: ...Solution Out of fuel Refuel Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and...

Page 109: ...spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge bat...

Page 110: ...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 and tighten Low battery volt...

Page 111: ...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 112: ...n 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 failures...

Page 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...114 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 119: ...115 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 120: ...116 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...43 Cargo Box Dumping 44 Chart Periodic Maintenance 50 54 Chrome Wheel Care 96 Cleaning and Storage 94 98 Cleaning the Exhaust System 74 75 Cleaning the Spark Arrestor 74 75 Clutching 101 Component Loc...

Page 122: ...earcase 61 Transmission 61 Fluid Levels During Storage 98 Fluid Recommendation Coolant 66 Engine Oil 56 Gearcases 60 Fogging the Engine 98 Fouled Plugs 65 F Freeplay Adjustment Throttle 77 Freeplay Th...

Page 123: ...lic Lands 49 Operator Safety 10 17 Outlets Auxiliary 20 P Park Brake 25 Park Brake Adjustment 80 Park Brake Inspection 79 Parking on an Incline 41 Parking the Vehicle 46 Periodic Maintenance Chart 50...

Page 124: ...le Freeplay 76 Throttle Freeplay Adjustment 77 Throttle Freeplay Inspection 76 Throttle Pedal 24 Throttle System 76 77 Tilt Steering 24 Tires 82 83 Nut Torque 82 Tread Depth 82 Wheel Installation 83 W...

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Polaris Ranger 4X4, Owner'S Manual

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