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Polaris RANGER CREW SP 570 NorthStar Edition, Owner'S Manual, Page: 112 / 186

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Polaris RANGER CREW SP 570 NorthStar Edition Owner'S Manual Download Page 112

TRANSMISSION (MAIN GEARCASE)

Always check and change the transmission oil at the intervals outlined in the
POLARIS Maintenance Schedule beginning on page 99. Maintain the oil level
even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart for recommended lubricants,
capacities and torque specifications. See page 159 for the part numbers of
POLARIS products.

110

MAINTENANCE

Summary of Contents for RANGER CREW SP 570 NorthStar Edition

Page 1: ...OWNER S MANUAL For Maintenance and Safety RANGER SP 570 RANGER CREW SP 570 2022 ...

Page 2: ...ne except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious ...

Page 3: ...2022 Owner s Manual RANGER SP 570 RANGER SP 570 Premium RANGER SP 570 NorthStar Edition RANGER CREW SP 570 RANGER CREW SP 570 Premium RANGER CREW SP 570 NorthStar Edition ...

Page 4: ...demark of Google LLC BatteryMINDer is a registered trademark of VDC Electronics Inc Apple and APP Store are registered trademarks of Apple Inc NYOGEL is a registered trademark of Nye Lubricants Inc Copyright 2022 Polaris Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality ...

Page 5: ... 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 information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Maste...

Page 6: ...4 WELCOME ...

Page 7: ...ction 7 Safety 11 Features and Controls 35 Operation 67 Winch Guide 85 Emission Control Systems 97 Maintenance 99 Specifications 153 POLARIS Products 159 Troubleshooting 161 Warranty 167 Maintenance Log 177 5 ...

Page 8: ...6 ...

Page 9: ...erate this vehicle without proper instruction Take an authorized training course See the Safety Training section for more information 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 Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times ...

Page 10: ...RNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components The Prohibition Safety Si...

Page 11: ...lace An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost q Vehicle Identification Number VIN w Engine Serial Number Vehicle Model Number Vehicle Identification Number VIN Engine Serial Number Key Number 9 INTRODUCTION ...

Page 12: ... do the following View vehicle specific information Access your Polaris Garage Download and view the owner s manual View accessory instructions Watch helpful videos Access warranty information Check for service notifications RIDE COMMAND WITH NFC Additional NFC features are available when using the Ride Command mobile app To access these features do the following 1 Download the Ride Command mobile...

Page 13: ...ulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals For more information about recreational off road vehicle safety in the United...

Page 14: ... restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow q Helmet w Eye Protection e Long Sleeves r Gloves t Long Pants y Over the Ankle Boots HELMET Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safe...

Page 15: ...henever riding this 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 8 Z87 1 or CE Make sure protective eye wear is kept clean GLOVES Wear gloves for comfort and for protection from sun cold weather and other elements BOOTS Wear sturdy over the ankle boot...

Page 16: ...comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label BELT WARNING The Belt Warning label is located on the clutch cover WARNING Improper service or maintenance of this PVTsystem can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around clut...

Page 17: ...d other changes in traction and terrain Avoid paved surfaces Avoid side hilling riding across slopes Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow 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 o...

Page 18: ...n ruts and other changes in traction and terrain Avoid paved surfaces Avoid side hilling riding across slopes Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow 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 designa...

Page 19: ...duce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Read Operation Maintenance Manual for more detailed loading information RANGER RANGER SP 570 RANGER SP ...

Page 20: ...CREW SP 570 RANGER CREW SP 570 PREMIUM RANGER CREW SP 570 NORTHSTAR EDITION MAXIMUM CARGO BOX LOAD 500 226 kg 500 226 kg 500 226 kg TIRE PRESSURE IN PSI KPa Front 16 110 Rear 16 110 Front 16 110 Rear 16 110 Front 16 110 Rear 16 110 MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES 1225 510 kg 1100 499 kg 750 340 kg Read Operation Maintenance Manual for more detail...

Page 21: ...t with back against seat feet flat on the floor and hands on steering wheel or handholds Stay completely inside the vehicle Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk to injury Keep a firm grip on the steering wheel or handholds and brace yourself Do not put any part of your body outside of the vehicle for any reason Part number 73...

Page 22: ...hicle is stopped place shift in parked position Part number 7300582 English 7300582 F French Canadian CLUTCH COVER WARNING The Clutch Cover Warning label is located on the clutch cover WARNING 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...

Page 23: ...ION The Air Filter Caution label is located on the air filter housing CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing filter ensure there is no dirt or debris in the clean side of the intake tube The air filter must be properly seated before the lid is reinstalled Please reference your owner s manual for additional in...

Page 24: ...orboards 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 rollover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is approved for on road operation Never consume alcohol or drugs before or while operating this vehicle Never ope...

Page 25: ...pping 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 s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain ...

Page 26: ...terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase 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 of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehic...

Page 27: ...OPERATION section of the owner s manual for proper operating procedures OPERATING WITHOUT INSTRUCTION Operating 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 All operators must read and understand the Owner s Manual and all warning and instruction l...

Page 28: ...ll riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold if equipped USING ALCOHOL OR DRUGS Never consume alcohol or drugs before or while operating this vehicle Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception...

Page 29: ...imes PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield JUMPS AND STUNTS CAUTION Exhibition driving increases the risk of an accident or rollover DO NOT do po...

Page 30: ... latches are secure before operating the vehicle Always inspect cab nets and latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Your POLARIS dealer can assist FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehi...

Page 31: ...n the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passengers accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow ...

Page 32: ...an cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas IMPROPER TIRE MAINTENANCE WARNING Operating this vehicle with improper tires or with improper or uneven t...

Page 33: ... Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual STALLING WHILE CLIMBING A HILL CAUTION Stalling or rolling backwards while climbing a hill could cause a rollover Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is ...

Page 34: ...st verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you 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 your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water OPERATING A DAMAGED VEHICLE C...

Page 35: ...EFUELING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks NEVER carry fuel or other flammable liquids on this vehicle Failure to follow this instruction could lead to serious burn injuries o...

Page 36: ...34 ...

Page 37: ...r Protection System w Headlight e Front Bumper Brush Guard rTie Down Point t Radiator behind removable grille y Cargo Box u Tailgate i Muffler Spark Arrestor o Cargo Box Lever a Fuel Cap s Seatbelt d Electrical Compartment under seat 35 FEATURES AND CONTROLS ...

Page 38: ...rickle Charging Port w Instrument Cluster i Storage Compartment e Ignition Switch o 12V Auxiliary Port r 12V Auxiliary Port a Right Switch Panel t Gear Selector Shifter s Steering Wheel Adjustment Lever y Cup Holder 36 FEATURES AND CONTROLS ...

Page 39: ... Switch Panel t Gear Selector Shifter s Steering Wheel Adjustment Lever y Battery Trickle Charging Outlet ADJUSTABLE STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference Lift 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 37 FEATURES AND CONTROLS ...

Page 40: ...charger PN 2415295 which can be ordered through your dealer Polaris provides a charging accessory with your vehicle that allows easy connection to the battery through the Battery Trickle Charging Outlet located on the dash While charging place the charger outside of the vehicle and protect it from moisture GEAR SELECTOR Low gear is the primary driving range for the RANGER High gear is intended for...

Page 41: ...ny of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads Driving frequently at low RPM or at ground speeds below 11 km h 7 MPH SWITCHES MODE BUTTON The MODE button is located on the instrument cluster Use the MODE button to toggle through mode options available in the instrument cluster IGNITION SWITCH The ignition switchq is...

Page 42: ... ON position when released DRIVELINE MODE SWITCH The Driveline Mode Switch has three positions All Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off Turf Mode q AWD Press the top of the switch to engage All Wheel Drive AWD w 2WD Move the switch to the center position to lock the differential and operate in two wheel drive 2WD e TURF Mode Press the bottom of the switch for Turf Mode unl...

Page 43: ...ottle pedal and brake pedal are applied simultaneously engine power may be limited BRAKE PEDAL Depress the brake pedal w to slow or stop the vehicle Apply the brakes while starting the engine 41 FEATURES AND CONTROLS ...

Page 44: ...r seats WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the vehicle To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch q downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagona...

Page 45: ... housings regularly SEAT AND STORAGE COMPARTMENTS The electrical compartment is located under the center rear most seat Never use this area for storage Storage compartments are located under all other seats Remove the storage bin under the right rear most passenger seat to access the battery If your model is equipped with a storage console and cup holders located between the front seats lift the c...

Page 46: ...rting the engine the EPS system is inoperative See your POLARIS dealer or other qualified person as soon as possible for repair Continued operation could result in permanent damage to the EPS unit and increased steering effort FUEL CAP NOTICE Never use fuel blends with more than 10 ethanol Engine damage could occur The fuel tank filler cap q is located on the right hand side of the vehicle near th...

Page 47: ...nd latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Your POLARIS dealer can assist SECURING THE NET 1 After entering the vehicle connect the latch q at the top edge of the net to the receiver latch mounted on the front frame OPENING THE NET 1 T...

Page 48: ...rotection 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 TRAILER HITCH BRACKET This vehicle is equipped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage alwa...

Page 49: ...er trip meter trip meter 2 voltage engine temperature engine hour meter programmable service hour interval ground speed or engine RPM e Display Area 1 This area displays engine RPM ground speed or coolant temperature r Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon w...

Page 50: ...rs Serious engine damage could result Your authorized POLARIS dealer can assist EPS Warning if equipped This indicator illuminates when a fault has occurred in the EPS system Your authorized POLARIS dealer can assist EPS operation is possible with key on engine off for up to 5 minutes Engine Hot This lamp illuminates to indicate an overheated engine If the indicator flashes a severe overheating co...

Page 51: ...ates when the headlamp switch is set to high beam Brake Failure if equipped Lamp illuminates when Brake System if Brake Failure Alarm is equipped detects low fluid level in brake hydraulic system Verify brake fluid in reservoir 49 FEATURES AND CONTROLS ...

Page 52: ...nformation displayed in Area 1 q DISPLAY AREA 1 FUNCTION Speed The vehicle s speed will be displayed in mph or km h Engine Temperature The vehicle s current engine temperature will be displayed RPM The vehicle s RPM will be displayed 50 FEATURES AND CONTROLS ...

Page 53: ...re will be displayed Trip 1 The vehicle Trip 1 mileage will be displayed Trip 2 The vehicle Trip 2 mileage will be displayed RPM The vehicle RPM will be displayed Voltage The vehicle s current battery voltage will be displayed Speed The vehicle s current speed will be displayed Engine Hours The vehicle s engine hours will be displayed Service Hours The vehicle s service hours will be displayed 51 ...

Page 54: ...U NOTES Diagnostic Codes Only displays if fault codes are present or stored Advanced Menu if equipped Set maximum speed and geofencing settings Units Distance Select MPH or KPH Units Temp Select between F and C Clock if equipped Select between 12H or 24H and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View Set Service hours Exit ...

Page 55: ...ds before showing first menu item 2 Select Diagnostic Codes from the Options Menu by pressing the MODE button Toggle the Up Down Buttons to cycle through Code s NOTICE This option will only be available if a fault code was set or is active during the current ignition key on cycle Turning off the ignition will clear any save fault codes from the gauge q Display area 1 will show FMI w Display area 2...

Page 56: ...and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 5...

Page 57: ...r Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Driver Circuit Grounded 1347 4 Fan Relay Driver Circuit Driver Circuit Open Gr...

Page 58: ... Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too Low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent C...

Page 59: ...ove Normal Operational Range Most Severe Level 84 0 Data Erratic Intermittent Or Incorrect 84 2 Abnormal Rate Of Change 84 10 Received Network Data In Error 84 19 System Power Data Valid But Above Normal Operational Range Most Severe Level 168 0 Voltage Above Normal Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Engine Speed Data Valid But Above Normal Operatio...

Page 60: ...teering Torque Full Failure Condition Exists 520224 31 EPAS Inverter Temperature Data Valid But Above Normal Operational Range Most Severe Level 520225 0 Data Valid But Above Normal Operating Range Moderately Severe Level 520225 16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 ...

Page 61: ...irst menu item 2 Select Units Distance from the Options Menu by pressing the MODE button Reference the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or KPH e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu ...

Page 62: ...e the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units F or C e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will e...

Page 63: ... Cycles Hours t With the correct unit displayed Press the mode button which will set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displayed Press the mode button which will set the unit i Toggle the Up Down Buttons to change the units Cycles 1s of Minutes o With the correct unit displayed Press the mode button which will set the unit and r...

Page 64: ... image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Blue or Red e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will e...

Page 65: ...hown above q Press the MODE button w Toggle the Up Down Buttons to change the units Increase or De crease Level e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds whic...

Page 66: ...hours after they have counted down to 0 0 reselect the existing setpoint or select a new service hour value 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Options Menu PIN ACTIVATED SECURITY SYSTEM P A S S IF EQUIPPED INSTRUMENT CLUSTER The option...

Page 67: ...tinue until all four digits of your desired passcode have been selected Once finished NEW PIN SET will flash momentarily and then revert back to the REQUIRE PIN TO START screen Please record your passcode 5 To enable your new passcode use the UP DOWN toggle buttons to change the flashing OFF at bottom of screen to ON If this step is skipped P A S S will not be enabled 6 Press the MODE button to re...

Page 68: ...rrent passcode 4 Use the UP DOWN toggle buttons to change the flashing ON at bottom of screen to OFF 5 Press the MODE button to re enter the OPTIONS menu P A S S is now disabled You can exit the OPTIONS menu three different ways Toggle to EXIT and press the MODE button Hold the MODE button for a few seconds Do nothing allowing the system to automatically revert back to the main screen 66 FEATURES ...

Page 69: ...GER is the first 25 hours of operation or the time it takes to use the first two tanks full of fuel No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first 3 hours of operation will da...

Page 70: ... new vehicles as well as after a belt replacement A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from ...

Page 71: ...ch Push down on the seat back to ensure the latch is secure page 43 Seat Belt Check length of belt for damage check latches for proper operation page 43 Cab Doors If equipped Check doors and latches for wear or damage page 45 Riding Gear Wear approved helmet goggles and protective clothing STARTING THE ENGINE 1 Position the vehicle on a level surface outdoors or in a well ventilated area 2 Sit in ...

Page 72: ...e 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 Place the transmission in PARK 3 Engage the PARKING BRAKE if equipped 4 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 5 Turn the engine off WARNING A rolling vehicle can...

Page 73: ...ankle boots 2 Perform the pre ride inspection 3 Sit in the driver s seat and fasten the seat belt 4 Always use the cab nets or doors while riding in this vehicle 5 Place the transmission in PARK 6 Start the engine 7 Apply the service brakes and shift the transmission into gear 8 Check your surroundings and determine your path of travel 9 Release the park brake 10 Keeping both hands on the steering...

Page 74: ...cab nets or doors if equipped are properly secured Do not carry more than the recommended number of passengers for your vehicle Allow a passenger to ride only in a passenger seat 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 discomfort or injury to a passenger Vehicle handling...

Page 75: ...of skidding and sliding Follow these precautions when encountering slippery conditions Do not operate on excessively rough slippery or loose terrain Slow down before entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may ...

Page 76: ... 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 When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Always descend a hill with the direction selector swi...

Page 77: ... 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 vehicle 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal NOTICE After running your vehicle in water it s critical that you perform the services outlined...

Page 78: ...o the following 1 Apply the brakes 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 Place the transmission in PARK 4 Turn the engine off 5 Engage the PARKING BRAKE if equipped 6 Slowly release the brake ped...

Page 79: ...and drive in the lowest gear available Always use LOW gear when towing or hauling heavy loads SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra cautio...

Page 80: ...ssengers must always ride in the cab with seat belts fastened securely TOWING A RANGER Towing this vehicle is not recommended Always transport the vehicle on a trailer or flatbed with all four wheels off the ground If towing a disabled vehicle is unavoidable place the disabled vehicle s transmission in neutral Tow the shortest distance possible Do not operate faster than 16 km h 10 MPH TOWING LOAD...

Page 81: ...ing off road MODEL TOTAL TOWED LOAD WEIGHT LEVEL GROUND TOTAL TOWED LOAD WEIGHT 15 GRADE TOTAL HITCH VERTICAL WEIGHT MAXIMUM TOWING SPEED RANGER 570 680 4 kg 1500 lbs 386 kg 850 lbs 68 1 kg 150 lbs 16 km h 10 MPH BELT LIFE To extend belt life use low gear when hauling or towing heavy cargo Using high gear for heavy loads hilly terrain or in wet muddy conditions will increase the chance of drive be...

Page 82: ...nly or at the front of the box 6 Stand clear and pull up on the cargo box release lever q 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 is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires could also catch the rea...

Page 83: ...nter to indicate that the vehicle is in AWD When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Initially the vehicle s electronic system will not enable the AWD until the engine RPM is b...

Page 84: ...itions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed UNLOCKING THE DIFFERENTIAL TURF MODE When operating in TURF mode the inside rear wheel will rotate independently from the outside wheel during turns Operate in TURF mode only as needed to protect smooth level surfaces from tire damage DO NOToperate in TURF mode when climbing or descending h...

Page 85: ...igh speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential WARNING Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the switch to AWD before ascending or descending a hill 83 OPERATION ...

Page 86: ...84 ...

Page 87: ...he winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 94 7 Always keep the area around the vehicle 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 u...

Page 88: ...thout warning 14 Never attempt to winch loads that weigh more than the winch s rated capacity 15 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 16 Never touch push pull or straddle the winch cable while winching a load 17 Never let the ...

Page 89: ...s 23 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 24 Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable 87 WINCH GUIDE ...

Page 90: ...ing 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 ...

Page 91: ... put your fingers into the hook This could lead to SEVERE INJURY Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable TIP A tow strap is NOT intended to stretch A recovery strap is designed to stretch 89 WINCH GUIDE ...

Page 92: ...ng of the winch cable and reduce the load on the fairlead 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 kill trees Please remember to Tread Lightly treadlightly org Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the...

Page 93: ...may result in winch cable failure 10 Never use straps chains or other rigging items that are damaged or worn 11 The ONLY time a winch equipped vehicle should be 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 94 For y...

Page 94: ...re than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching 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...

Page 95: ... this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition 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...

Page 96: ...xtra 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 possibly lead to an...

Page 97: ...r your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer or other qualified person 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 p...

Page 98: ...96 ...

Page 99: ...ic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located on the inside of the lower left frame tube below driver s foot area ELECTROMAGNETIC INTERFERENCE This vehicle complies with the EMC requirements of UN ECE Regulation 10 Non ionizing Radiation This vehicle emits some e...

Page 100: ...98 ...

Page 101: ...n reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions related service Record maintenance and service in the Maintenance Log beginning on page 177 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perfor...

Page 102: ...EAK IN SERVICE FIRST 25 HOURS 250 MILES 400 KM Engine Oil and Filter Change the engine oil and filter The break in period consists of the first 25 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components The items outlined in this service interval only need to be performed at the first 25 hours of opera...

Page 103: ...ke fluid from a sealed container if needed Inspect brake pad wear Cooling System Fluid level inspection inspect for fluid leaks add coolant if needed Inspect coolant strength seasonally pressure test system yearly Drive Belt Inspect replace as needed Engine Breather Inspect clean as needed Engine Oil and Filter Change the engine oil and filter Exhaust Silencer Pipe Inspect for leaks or damage Fuel...

Page 104: ...eather operation EVERY 200 HOURS 2000 MILES 3200 KM OR YEARLY Front Gearcase Fluid Change fluid Shock Absorbers Replace as needed Spark Plug Replace as needed Transmission Fluid Change fluid Valve Clearance Inspect adjust as needed Have an authorized Polaris dealer or other qualified person perform these services Vehicles subjected to severe use must be serviced at 50 of the stated interval Exampl...

Page 105: ...uld be lubricated at the general lubrication interval ITEM LUBE METHOD Engine Oil PS 4 5W 50 4 Cycle Oil Add to proper level on dipstick See page 104 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 128 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 110 Front Gearcase Oil Demand Drive Fluid See page 112 Front Prop Shaft Yoke U Joint Grease...

Page 106: ... removing the dipstick OIL CHECK The oil dipstick q is located on the engine Access the dipstick through the right rear wheel well NOTICE Oil level should be checked when the engine is cold 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick Wipe it dry with a clea...

Page 107: ...6 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL w and ADD e marks Do not overfill 7 Reinstall and tighten the dipstick 105 MAINTENANCE ...

Page 108: ...ain plug q is located on the bottom of the crankcase Use a 6mm hex bit socket or equivalent 1 Position the vehicle on a level surface Place the transmission in PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 106 MAINTENANCE ...

Page 109: ... plug q 5 Allow the oil to drain completely 6 Install a new sealing washer w on the drain plug TIP The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug TORQUE 12 ft lbs 16 Nm 107 MAINTENANCE ...

Page 110: ...w filter with a film of fresh engine oil Check to make sure the o ring is in good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional 3 4 turn 12 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the oil cap r or the dipstick t and fill the sump with 1 9 liters 2 qts of reco...

Page 111: ... bring the level to the upper mark on the dipstick 18 Dispose of used filter and oil properly GEARCASES GEARCASE SPECIFICATION CHART GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG LEVEL CHECK PLUG TORQUE Main Gearcase Transmission AGL Gearcase Lubricant Transmission Fluid 1200 ml 40 6 oz 14 ft lbs 19 Nm 14 ft lbs 19 Nm Front Gearcase Demand Drive Fluid 200 ml 6 8 oz 12 ft lbs 16 Nm 12 ft ...

Page 112: ...the POLARIS Maintenance Schedule beginning on page 99 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 159 for the part numbers of POLARIS products 110 MAINTENANCE ...

Page 113: ...uid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug q 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification 111 MAINTENANCE ...

Page 114: ... bottom of the fill plug hole Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks Discard used fluid properly FRONT GEARCASE DEMAND DRIVE Always check and change the front gearcase oil at the intervals outlined in the POLARIS Maintenance Schedule beginning on page 99 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Speci...

Page 115: ... q is located 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 113 MAINTENANCE ...

Page 116: ...n under the drain plug w on the bottom right hand side 5 Remove the drain plug Drain the oil 6 Clean and reinstall the drain plug Torque to specification 7 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 114 MAINTENANCE ...

Page 117: ...NEW OR USED PLUG TORQUE NGK MR7F 0 7 0 8 mm 9 ft lbs 12 Nm NOTICE When installing spark plugs into the engine do not use anti seize SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation The spark plug firing end 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 CAUTION A hot ex...

Page 118: ...ovided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation 4 Torque to specification NOTICE When reinstalling the spark plug boot onto the spark plug be sure to place a small amount of dielectric grease in the spark plug boot 116 MAINTENANCE ...

Page 119: ...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 tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or poor...

Page 120: ...d fresh Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed RADIATOR AND COOLING FAN Always check and clean the screen and radiator fins at the intervals outlined in the POLARIS Maintenance Sch...

Page 121: ...he opening 4 Use a funnel and slowly add coolant as needed TIP This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle w has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Your POLARIS dealer can ...

Page 122: ...h the instructions in this warning can result in severe injury or death Do not modify any component of the PVTsystem Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVTsystem rotates at high speeds creating lar...

Page 123: ...he following 1 Position the vehicle on a level surface Place the transmission in park 2 Lift the cargo box 3 Remove the eight 8 fasteners securing the clutch cover q Each fastener can be removed using a 8mm socket with ratcheting wrench and extension 4 Pull the bottom of the cover outward and over the suspension to remove it 5 Make sure the cover gasket does not fall out of the groove when removin...

Page 124: ...bris from the entire clutch air duct passage 11 Check for signs of damage to seals on the transmission and engine If any seals appear to be damaged your vehicle requires prompt service Your POLARIS dealer can assist TIP Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slowe...

Page 125: ... Rotate spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install the clutch cover into wheel well by installing the top half first then the bottom half over the suspension NOTE Use care when installing the clutch cover Do not damage cover intake boot or electrical harness 6 Install all clutch cover screws Torque to specification TORQUE PVT Ou...

Page 126: ...install 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 five 5 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 belt slips re...

Page 127: ...ry least to water below the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Remove the spark plugs Turn the engine over several times using the electric start 4 Dry the spark plugs and reinstall or replace with new plugs 5 Attempt to start the engine If necessary repeat the drying procedure 6 Take the vehicle in for service as soon as possible ...

Page 128: ...sure the seal is not torn and has been maintaining a proper seal 4 Inspect the air filter and air box for dirt debris oil or water If the filter needs to be replaced remove the worm gear clamp from the filter neck with a flat blade screwdriver or 6mm socket Slide the filter rearward to remove it from the boot then lift it straight upward and out of the air box 5 With the filter removed clean the i...

Page 129: ...after installation Tighten the worm gear clamp to 3 Nm 26 in lbs 8 Reinstall the air box cover Make sure both hinges are fully inserted Secure the cover clips SPARK ARRESTOR WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrester while the system is hot Allow components to cool sufficient...

Page 130: ... components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Replace the arrestor if damage is found 4 Reinstall the arrestor 5 Torque the bolt and nut to specification NOTICE Spark Arrestor Bolt 10 ft lbs 13 5 N m BRAKES The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes BRAKE FL...

Page 131: ...or if the type and brand of the fluid in the reservoir q 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 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 open the hood and add brake fluid to the upper MAX line 4 Apply the brake forcefully fo...

Page 132: ...cessive wear Change pads when worn to 0 762 mm 0 030 q STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the POLARIS Maintenance Schedule 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 20 25 mm 0 8 1 0 of freeplay 4 If there is excessive freeplay or strange noises or...

Page 133: ...which could result in serious injury or death Always replace tires when the tread depth measures 1 8 in 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure Always use POLARIS approved size and type of tires for this vehicle when replac...

Page 134: ...y for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Lug Nut Aluminum Wheels Front and Rear 41 Nm 30 ft lbs 90 1 4 Turn Lug Nut Steel Wheels Front and Rear 49 Nm 36 ft lbs Hub Retaining Nut Front 122 Nm 90 ft lbs Front CREW 122 Nm 90 ft lbs Rear 150 Nm 111 ft lbs Rear CREW 245 Nm 181 ft lbs 132 MAINTENANCE ...

Page 135: ...ffect 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 Your dealer can assist 1 Place the transmission in PARK 2 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Attach the wh...

Page 136: ...134 MAINTENANCE ...

Page 137: ...use may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse The fuse box is located under the hood Spare fuses are provided in the fuse box If you suspect that a fuse or relay may not be working properly your dealer can assist FUSE SIZE FEATURE SUPPORTED 20A Chassis 15A Lights 10A Key Switch 10A Trickle Charge 10A ECM 15A Drive 30A EPS 2...

Page 138: ...p HEADLIGHT LAMP REPLACEMENT CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing To replace the headlight lamp do the following 1 Access the headlamp wiring harnesses through the front hood 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector q not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp TIP Make ...

Page 139: ...the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes Start the engine Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 20 cm 8 below the mark placed on the wall Include the weight of a rider on the seat while performing this step 137 MAINTENANCE ...

Page 140: ...eps 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 before each ride To check the brake lights do the following 1 Turn the key to the ON position 2 Depress the brake pedal The brake light should come on after about 0 4 in 10 mm of pedal travel If the light doesn t come on check the bulb 138 MAINTENANCE ...

Page 141: ...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 water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARN...

Page 142: ...red 1 Ensure that the battery is fully charged 2 Place the fully charged battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries 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 contact with electrolyte WARNING Battery gases could accumulate in ...

Page 143: ...aled and fully charged at the factory Never pry 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 strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or ...

Page 144: ...d slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours Using constant current charger standard amps specified on top of battery 142 MAINTENANCE ...

Page 145: ...se using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products 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 first and the lower parts last 2 Rinse with clean wa...

Page 146: ... 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 labels Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Door seals if equipped Cab and body panels Labels and decals Electrical components and wiring Air intake com...

Page 147: ...posits 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 Change the oil and filter See the Engine Oil section AIR FILTER AIR BOX Replace the air filter See Maintenance Chapter Clean the air box FLUID LEVELS Inspect the fluid levels Add or change fluids as recommended i...

Page 148: ...forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 Reinstall the spark plug caps 7 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline BATTERY MAINTENANCE See page 141 and page 141 for storage and charging procedures STORAGE AREA COVERS Be sure the storage area is well v...

Page 149: ...aily Pre Ride Inspection Tightness of the bolts nuts and other fasteners should be checked by an authorized dealer or other qualified service facility 5 Lubricate at the intervals outlined in the POLARIS Maintenance Schedule 147 MAINTENANCE ...

Page 150: ...ORKING LOAD LIMIT WARNING Always secure cargo properly Improperly securing a load can result in severe injury or death Securing devices such as tie down straps are manufactured to support a load that can be applied during normal service This is known as the Working Load Limit WLL VEHICLE TYPE TIE DOWN MINIMUM WLL All Vehicles 3 300 lb 1497 kg TRANSPORTING THE VEHICLE Follow these procedures when t...

Page 151: ...r to transport WARNING Do not exceed the towing vehicle s or trailer s towing capacity when transporting Refer to the towing vehicle and trailer s specifications WARNING If transporting the vehicle in a non enclosed trailer the vehicle must FACE FORWARD or the roof must be removed Failure to comply may allow airflow vibration or other factors to separate the roof from the vehicle and cause an acci...

Page 152: ... cargo CAUTION Always use the provided tie down points Not using the provided vehicle tie down points could lead to premature component failure and or excess wear on the tie down straps WARNING Always secure the vehicle with at least four straps when trailering Use two straps in the front and two in the rear WARNING Never use chains to tie down the vehicle WARNING Do not lay straps over any sharp ...

Page 153: ...TIE DOWN LOCATIONS q Front tie down point w Rear tie down points 151 MAINTENANCE ...

Page 154: ...152 ...

Page 155: ...FR 1928 53 Fuel Capacity 9 5 gal 36 L Engine Oil Capacity 2 qts 1 9 L with filter Coolant Capacity 5 qts 4 75 L Overall Length 108 in 290 cm Overall Width 56 in 152 4 cm Overall Height 74 in 188 cm Wheelbase 73 in 202 cm Cargo Box Dimensions Inside 33 3x48 7x12 3 in 84 5x123 7x31 2 cm Ground Clearance 11 in 27 9 cm NorthStar Models 10 5 in 26 7 cm Min Turning Radius 152 in 386 7 cm Towing Capacity...

Page 156: ...ravel Rear Suspension Dual A Arm IRS w 10 in 25 4 cm of travel Throttle Body Size 42 mm Ignition System Digital CDI Driving System Type PVT Shift Type Single Lever H L N R P Gear Reduction Low 28 84 1 Gear Reduction Reverse 25 82 1 Gear Reduction High 13 57 1 Drive Ratio Front 3 818 1 Tire Size Front 25 x 8 x 12 Tire Size Rear 25 x 10 x 12 Tire Pressure Front 10 psi 69 kPa Tire Pressure Rear 10 ps...

Page 157: ...75 kg NorthStar Models 1857 lbs 842 32 kg Test GVW Rollover Protection System ROPS 2700 lbs 1224 7 kg per OSHA 29 CFR 1928 53 Fuel Capacity 9 5 gal 36 L Engine Oil Capacity 2 qts 1 9 L with filter Coolant Capacity 5 qts 4 75 L Overall Length 144 in 365 76 cm Overall Width 56 in 142 2 cm Overall Height 74 in 188 cm Wheelbase 105 in 266 7 cm Cargo Box Dimensions Inside 33 3x48 7x12 3 in 84 5x123 7x3...

Page 158: ...MR7F 031 0 7 0 8 mm Lubrication System Wet Sump Cooling Liquid Front Suspension MacPherson Ride Strut w 9 in 22 9 cm of travel Rear Suspension Dual A Arm IRS w 10 in 25 4 cm of travel Throttle Body Size 42 mm 570 Ignition System Digital CDI Driving System Type PVT 4 wheel independent shaft lockable differential Shift Type Single Lever H L N R P Gear Reduction Low 28 84 1 Gear Reduction Reverse 25 ...

Page 159: ...rake Light 10 L E D 3 1W CLUTCHING CHART CLUTCH SETTINGS ALTITUDE meters feet DRIVE CLUTCH DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Helix 0 1800 0 6000 2 Seat 1327263 41 77 CREW 1327263 41 77 2 Seat 7043789 CREW 7045855 2 Seat 7045854 CREW 7045854 2 Seat 1336970 CREW 1336970 1800 3700 6000 12000 2 Seat 1327265 41 68 CREW 1327265 41 68 2 Seat 7043789 CREW 7045855 2 Seat 7045854 CREW 7...

Page 160: ...158 ...

Page 161: ...bricant Transmission Fluid 3 8 l 1 gal 2877922 Demand Drive Fluid 95 l 1 qt 2877923 Demand Drive Fluid 3 8 l 1 gal 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix 95 l 1 qt 2880513 Antifreeze 50 50 Premix 3 8 l 1 gal Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 89 ml 3 oz cartridge 2871423 All Season Grease 414 ml 14 oz ...

Page 162: ...bilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 5253552 POLARIS Battery Strap Bracket for 45 AH Battery 4015591 POLARIS 30 AH Battery 2521372 POLARIS Air Filter 160 POLARIS PRODUCTS ...

Page 163: ...ch WARNING Excessive throttle may cause loss of control and vehicle rollover 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 rollover Belt slippage from water or snow ingestion into the PVT system Dry out the PVT see ...

Page 164: ...OVER FAILS TO START POSSIBLE CAUSE 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 plug Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your authorized dealer can assist Low battery voltage Rech...

Page 165: ...Incorrectly installed spark plug wires Your authorized dealer can assist Mechanical failure Your authorized dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap...

Page 166: ...tery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Low fuel pressure See your POLARIS dealer Other mechanical failure See your POLARIS dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel ...

Page 167: ...k plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your authorized dealer can assist Overheated...

Page 168: ...166 ...

Page 169: ...dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration...

Page 170: ... ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in...

Page 171: ...TY 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 CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE TH...

Page 172: ...ation from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair IF YOU MOVE If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from cou...

Page 173: ...gistered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Dealership contacts can be found via this website if needed www polaris com en us contact Should your dealer require any additional assistance they will contact the...

Page 174: ...om the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty 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 c...

Page 175: ... OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND ...

Page 176: ... maintain replace or repair the emission control devices or systems on your vehicle An authorized POLARIS dealer or other qualified person can perform any service that may be necessary for your vehicle POLARIS also recommends POLARIS parts however equivalent parts may be used for such service It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer r...

Page 177: ...r Resources Board and Polaris Industries Inc is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle In California new off highway recreational vehicles must be designed built and equipped to meet the State s stringent anti smog standards Polaris must warrant the emission control system on your OHRV EVAP for the periods of time ...

Page 178: ... exceed 30 days As an OHRV EVAP owner you should also be aware that Polaris may deny you warranty coverage if your OHRV EVAP or a part has failed due to abuse neglect improper maintenance or unapproved modifications ADD ON OR MODIFIED PARTS An add on or modified part must be compliant with applicable CARB emission control standards A violation of this requirement is punishable by civil and or crim...

Page 179: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 177 MAINTENANCE LOG ...

Page 180: ...178 ...

Page 181: ...y 31 Diagnostic Display Code Definitions 54 Drive Belt Wear Burn 161 Driveline Mode Switch 40 Driving Downhill 74 Driving in Reverse 75 Driving on a Sidehill 74 Driving Procedures 71 Driving Through Water 74 Driving Uphill 74 Dumping the Cargo Box 79 E Electromagnetic Interference 97 Electronic Power Steering 44 Engine and Drivetrain Break in 68 Engine Backfires 163 Engine Doesn t Turn Over 162 En...

Page 182: ...ch Cover Warning 20 Fuel Transport Warning 21 Maximum Payload Warning 20 Passenger Tire Pressure Warning 17 Proper Use Warning 15 16 Seat Belt Drive Responsibly Warning 19 Lightning and Powerlines 33 Lights 136 Limited Warranty 167 Lubrication Recommendations 103 M Maintenance Oil and Filter Change 106 Oil Check 104 Maintenance Log 177 Maintenance Overview 99 Mode Button 39 N Near Field Communicat...

Page 183: ...at Belt 42 Seat Belts 27 Seat Removal 43 Shock Loading the Winch 94 Signal Words 8 Spark Arrester 97 Spark Arrestor 127 Spark Plug Gap Torque 115 Spark Plug Inspection 115 Spark Plug Recommendations 115 Specifications 153 155 Spring Adjustment 130 Stabilize the Fuel 145 Stalling While Climbing a Hill 31 Starting the Engine 69 Steering Wheel Inspection 130 Stopping the Engine 70 Storage 145 Storage...

Page 184: ...g the Vehicle 143 Welcome Page 3 Wet Fouled Plug 117 Wheel Installation 133 Wheel Removal 133 Winch Cable Care 93 Winch Maintenance and Service Safety 95 Winch Operation 88 Winch Safety Precautions 85 Winch Shock Loading 94 182 ...

Page 185: ......

Page 186: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Inc 2100 Highway 55 Medina MN 55340 Part No 9940229 Rev 01 Printed in USA ...

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