Polaris RANGER EV 2022 Page 109 Owner'S Manual Download

Page: 109 / 125

TROUBLESHOOTING

VEHICLE WILL NOT OPERATE

POSSIBLE CAUSE

SOLUTION

Low battery voltage

Recharge the battery overnight

Loose battery connections

Check all connections and tighten

Loose contactor connections

Check all connections and tighten

Loose electronic control box
connections

Inspect, clean, reinstall connectors

Required torque exceeds motor
capability

Apply the brakes and select low
range

MALFUNCTION INDICATOR
TROUBLESHOOTING

The malfunction codes will blink on the controller. The code definitions provided
here are for informational purposes only.

TIP

If the indicator illuminates due to a minor issue such as a low voltage condition

or a sequence fault (reversing direction without releasing the accelerator),

select neutral and turn the key off and on to clear the error. If the error does not

clear, please see your POLARIS dealer for diagnosis and repair.

# OF BLINKS

CODE DEFINITION

Data or configuration error

Sequence fault

Power fault

Contactor issue

Throttle input error

Voltage protection

Controller or motor out of temperature range

Software fault

107

TROUBLESHOOTING

Summary of Contents for RANGER EV 2022

Page 1: ...OWNER S MANUAL For Maintenance and Safety RANGER EV 2022 Lorem ipsum ...

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 EV ...

Page 4: ...pational Safety and Health Administration U S Dept of Labor MACPHERSON RIDE is a registered trademark of Aftermarket Auto Parts Alliance Inc Tread Lightly is a registered trademark of the United States Department of Agriculture Carlisle is a registered trademark of CARLISLE INTANGIBLE LLC High Lifter is a registered trademark of NIVEL PARTS MANUFACTURING CO Copyright 2021 Polaris Industries Inc Al...

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: ...Introduction 7 Safety 11 Features and Controls 35 Operation 51 Winch Guide 67 Maintenance 77 Specifications 101 POLARIS Products 105 Troubleshooting 107 Warranty 109 Maintenance Log 117 5 ...

Page 8: ...6 ...

Page 9: ...ings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Never operate this vehicle without proper instruction Take an authorized training course Visit www rohva org or call 866 267 2751 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 keep hands feet and all other body...

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: ...o do the following View vehicle specific information Access your Polaris Garage Download and view the owner s manual View accessory instructions Watch how to 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 12: ...fe place A 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 key switch must be replaced if all keys are lost q Vehicle Identification Number VIN w Key Number Vehicle Model Number Vehicle Identification Number VIN Motor Serial Number on side of motor Key Number 10 INTRODUCTION ...

Page 13: ...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 States visit www ro...

Page 14: ...res at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by 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...

Page 15: ...ircle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing a...

Page 16: ...anual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or 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 q Seat Belt Drive Responsibly Warning w Proper Use Warning 14...

Page 17: ...n on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants Driving on public roads may be hazardous and could be a violation of the law Part Number 7179978 FUEL TRANSPORT WARNING The Fuel Transport Warning q is located in the cargo box WARNING NEVER carry fuel or other flammable liquids on this vehicle Fai...

Page 18: ...maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid side hilling riding across slopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your ...

Page 19: ...g 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 Be careful if load extends over the side of the box RANGER MID SIZE LSV EV MAXIMUM CARGO BOX LOAD 500 lbs 226 kg TIRE PRESSURE IN PSI KPa FRONT 20 138 REAR 20 138 MAXIMUM WEIGHT CAPACITY INCLUDES...

Page 20: ... personal injury will void the warranty and can result in permanent damage to the vehicle Refer to your Owner s Manual or contact your local POLARIS dealer with any questions BATTERY CAUTION The Battery Caution label located on the dashboard q CAUTION Do not drive through water above the floor of the vehicle Battery damage will occur Batteries require regular maintenance Failure to maintain batter...

Page 21: ...NJURY For Global Service Contact Brammo Inc at www Brammo com BATTERY CHARGING WARNING The Battery Charging Warning is located on the dashboard w WARNING Do not attempt to charge batteries externally only use the vehicle s charging system Do not attempt to operate or charge the vehicle if battery damage has occurred Connect battery charger to properly rated electrical receptacle with GFCI Refer to...

Page 22: ...ERY START NOTICE NOTICE Reduced or no operation may occur at battery temperatures below 0 C 32 F See Owners Manual To self heat the batteries Plug vehicle into grid power OR Turn key to the ON position 20 SAFETY ...

Page 23: ...e seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold The driver and all passengers must wear helmets eye protection gloves long sleeve shirts long pants over the ankle boots and their seat belts at all times Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboar...

Page 24: ...stacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your ve...

Page 25: ...al and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license The operator must be tall enough to sit with back against...

Page 26: ...ROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear and footwear increases the risk of a serious injuries in the event of an accident Operator and or all passengers must always wear an approved helmet that fits properly gloves long sleeve shirt long pants over the ankle boots and eye protection goggles or face shield SEAT BELTS WARNING Riding in this ...

Page 27: ...re pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on 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 t...

Page 28: ...rating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops OPERATING ON PUBLIC ROADS WARNING Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use OPER...

Page 29: ...or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as described in this owner s manual DESCENDING HILLS IMPROPERLY CAUTION 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 CROSSING HILLSIDES CAUTION Driving on a sidehill is not reco...

Page 30: ...ill while applying light brake pressure to control speed OPERATING IN UNFAMILIAR TERRAIN CAUTION Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover CAUTION Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be al...

Page 31: ...operating over obstacles could cause loss of control or rollover Before operating in a new area check for obstacles Avoid operating over large obstacles such as large rocks and fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles OPERATING THROUGH WATER CAUTION Operating through deep or fast flowing water can cause loss of traction loss of control ...

Page 32: ...ding but not limited to seat belts rollover protection devices brakes throttle and steering systems IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling which could cause loss of control or an accident Always follow the instructions in this owner s manual for carrying cargo Never exceed the stated load capacity for this vehicle Car...

Page 33: ...traveling through tall grass especially dry grass and when traveling in muddy conditions Always inspect areas near the drive system after driving through tall grass weeds brush other tall ground cover and muddy conditions Promptly remove any grass debris or foreign matter clinging to the vehicle Pay particular attention to the drive system area VENTILATION WHEN CHARGING BATTERIES Failure to provid...

Page 34: ...s directed Modifications to your vehicle may negatively impact vehicle stability Failure of critical machine components may result from operation with any modifications especially those that increase speed or power This vehicle may become less stable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Do not install any non POLARIS approved accessory or ...

Page 35: ...le with the equipment on your vehicle and provides the greatest amount of forward clearance Always wear a helmet that meets or exceeds the specifications in this owner s manual Refer to the Safe Riding Gear section of this owner s manual for more information Use only POLARIS approved accessories FOR MORE INFORMATION ABOUT SAFETY IN THE UNITED STATES call POLARIS at 1 800 342 3764 33 SAFETY ...

Page 36: ...34 ...

Page 37: ...CONTROLS COMPONENT LOCATIONS q ROPS Frame y Front Bumper Brush Guard w Hip Bars u Cargo Box Release Lever e Seat Belt i Tailgate Latches r Cargo Box o Taillights t Headlight a Receiver Hitch 35 FEATURES AND CONTROLS ...

Page 38: ... o Headlight Switch a Key Switch BATTERY DISCHARGE INDICATOR The battery discharge indicator displays the amount of charge removed used from fully charged batteries When the batteries are fully charged the gauge will display 100 The charge status indicator will be solid green NOTE Avoid discharging the batteries below 20 on the discharge indicator 36 FEATURES AND CONTROLS ...

Page 39: ...ashing Reduced performance due to elevated temperature Steady Power delivery terminated to protect against overheating If either occurs stop the vehicle and turn the key off Allow the motor and controller to cool adequately before operating e Park Brake Steady Engaged park brake r Gear Postion Steady Selected gear HOUR METER The hour meter records and displays the hours of actual vehicle movement ...

Page 40: ...EY SWITCH Turn the key to the ON position to activate the electrical circuits Turn the key to the OFF position to disable all electrical circuits The key can be removed from the switch when it is in the OFF position DIRECTION SELECTOR SWITCH When the direction selector is in the center position the vehicle is in neutral The vehicle will not move if the accelerator pedal is depressed Push the top o...

Page 41: ...ck the differential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD Turf Mode This mode of operation is well suited to turf driving or when active traction is not needed HEADLIGHT SWITCH Press the top of the switch to turn the headlights on Press the bottom of the switch to turn the headlights...

Page 42: ...d will be limited to a maximum of 10 MPH 16 km h and regenerative braking increases to improve control in aggressive terrain Return the mode switch to high mode for normal operation Move the switch to the center position to select the maximum range mode Use this mode to operate the vehicle a greater distance or for a longer time period This mode limits both speed and torque to obtain the maximum d...

Page 43: ...type Capacity will be limited during this time Make sure vent caps are installed properly and securely during vehicle operation and battery charging Recharge batteries fully at the end of each day the vehicle is operated allowing adequate time for the charger to complete its charge cycle The batteries in this vehicle do not have a memory effect Frequent charging will extend their life Avoid chargi...

Page 44: ...perature which allows it to operate more efficiently and shorten charge times See pages 61 62 for charging procedures 1 Always use extension cords with the appropriate ratings for the country in which it is used In North America this is a UL rating The cords must also be rated for the conditions in which they are used such as being rated for protection from oil in a garage or workshop environment ...

Page 45: ...y on will also activate the battery heaters but battery power will be used quickly This method is not recommended if SOC is low NOTE The vehicle may require up to 45 minutes of charging for the batteries to reach operating temperature depending on their current internal temperature It may take additional time for the batteries to reach a 100 state of charge SOC OPERATING AND CHARGING PERFORMANCE C...

Page 46: ...icle will operate at reduced performance Above 140 F 60 C The vehicle will not operate High Temperature Charging 14 to 113 F 10 to 45 C The charger will charge batteries at the full charging rate 113 to 131 F 45 to 55 C The charger will charge at a reduced charging rate but only up to 80 SOC BATTERY CONDITIONING New batteries cannot initially hold all of their capacity The approximate capacity of ...

Page 47: ...er connector before servicing or unplugging any electrical components When disconnected the main power connector disconnects the battery pack from all electrical components with the exception of the contactor Before servicing the vehicle unplug the main power fuse This fuse is located inside the right front wheel well The main power connector is located under the cargo box behind the seats To disc...

Page 48: ...brake pads from excessive wear TIP This feature will not operate properly if the park brake connector or switch under the hood malfunctions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer or other qualified service person promptly if this feature fails to operate properly 1 To set the park brake apply the brakes 2 Pull the park brake lever upward as ...

Page 49: ...eering wheel adjustment lever while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Always make sure the steering wheel position does not impede proper operation of the brake pedal throttle pedal and all other controls 47 FEATURES AND CONTROLS ...

Page 50: ...or Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed To slow the vehicle release the accelerator pedal Electric motor braking provides braking when the pedal is released For additional speed control or to stop the vehicle apply the service brakes SEATS SEAT REMOVAL Pull up on the front of the seat and slide it toward the front of the vehicle Install t...

Page 51: ...eats 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 diagonally...

Page 52: ...e to flush out the retractor and latch housings regularly CHARGING CORD The charging cord is located under the hood on the right side of the vehicle See page 62 for charging instructions AUXILIARY 12 VOLT TERMINAL BOARD The 12 volt terminal board is located under the hood It contains constant 12 volt switched 12 volt and ground terminals that can be used to power auxiliary lights and accessories T...

Page 53: ... areas are by contacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails TRAIL ETIQUETTE Always practice good ...

Page 54: ...pressure page 88 Wheels fasteners Inspect ensure fastener tightness page 88 Frame nuts bolts fasteners Inspect ensure tightness Accelerator Ensure proper operation Headlamps Check operation apply POLARIS dielectric grease when lamp is replaced page 90 Brake light tail lamps Check operation Seat Latch Push down on the seat back to ensure the latch is secure Seat Belt Check length of belt for damage...

Page 55: ...erate at a speed that s appropriate for the terrain the visibility and operating conditions and your skills and experience Never operate at excessive speeds Never attempt wheelies jumps or other stunts Keep both hands on the steering wheel or handlebars during operation 8 Never consume alcohol or drugs before or while operating this vehicle 9 Always use the size and type of tires specified for you...

Page 56: ...Release the park brake 10 Check your surroundings and determine your path of travel 11 Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 12 Drive slowly Practice maneuvering and using the accelerator and brakes on level surfaces 13 Do not carry a passenger until you have at least two hours of driving experience wit...

Page 57: ...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 58: ...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 59: ...ow these precautions 1 Avoid excessively steep hills 2 Always travel straight uphill 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces 5 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 6 Never go over the crest of a hill at high speed An obstacle a sharp ...

Page 60: ...m and batteries if the vehicle is operated in water deeper than the floorboards Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water 5 After leaving water always dry the brakes by app...

Page 61: ... 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 Set the park brake 4 Turn the key off Remove the key to prevent unauthorized use PARKING ON AN INCLINE Avoid parking on an incline if possible If...

Page 62: ...y engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage TIP AWD will not engage initially until speed is less than 5 MPH 8 km h Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the accelerator before switching to AWD NOTE Switching to AWD while the...

Page 63: ...whenever aggressive traction is not required DISENGAGING AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and...

Page 64: ...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 caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situatio...

Page 65: ...e cargo box 7 Release the tailgate latches WARNING Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders 8 Stand clear and pull up on the cargo ...

Page 66: ...rough terrain while cornering or while ascending or descending a hill 5 Do not tow more than the recommended weight for the vehicle 6 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location which could result in loss of control of the vehicle 7 The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacit...

Page 67: ...e parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport If transporting the vehicle in a non enclosed trailer then the vehicle must FACE FORWARD or roof must be removed Failure to comply may allow airflow vibration or other factors to separate the roof from the vehicle and cause an accident resulting in serious personal...

Page 68: ...en towing the vehicle 1 Turn the key to the off position 2 Always follow these precautions when towing this vehicle Do not operate faster than 10 MPH 16 km h Do not tow on public streets Do not allow passengers in the towed vehicle Avoid abrupt starts and stops Avoid sharp turns and abrupt steering maneuvers Avoid towing on a hill 66 OPERATION ...

Page 69: ...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 75 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 70: ...nds 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 winch cable run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or t...

Page 71: ...king Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter o...

Page 72: ...n be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 75 Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch...

Page 73: ... Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 8 Read and adhere to the following information for w...

Page 74: ...when winching a vehicle free a Release the winch clutch and spool out the necessary length of winch cable b Align the winch cable as close as possible to the winching vehicle s centerline c Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual d Re engage the clutch on the winch e Slowly winch in the slack in the winch cable f Select the...

Page 75: ... if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task a Release the clutch on the winch b Feed out the winch cable that is unevenly bunched up in one area c Re engage the winch clutch d Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook strap e Slowly winch t...

Page 76: ... 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 77: ...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 78: ...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 79: ...ual Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent pa...

Page 80: ... maintenance and service in the Maintenance Log ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HOURS CALENDAR D Steering Pre Ride Inspect operation Make adjustments as needed XU Front Suspension Pre Ride XU Rear Suspension Pre Ride Tires Pre Ride XU Brake Fluid Level Pre Ride XU Brake Pedal Travel Pre Ride Brake Systems Pre Ride Wheels Fasteners Pre Ride Frame Fasteners Pre Ride Batteries...

Page 81: ...s Check fastener torque Check that cotter pins are in place on castle nuts Lubricate stabilizer bar pivots and A arm joints XU Shock absorbers 50 H Inspect for leaks loose joints and wear XU Wiring 100 H 12 Months Inspect for wear routing security apply dielectric grease to non sealed connectors subjected to water mud etc D Front Wheel Bearings 100 H 12 Months Inspect replace as needed D Brake Flu...

Page 82: ...r severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval ITEM LUBE METHOD Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 85 Main Gearcase Oil Transaxle ATV Angle Drive Fluid See page 81 Front Gearcase Oil Demand Drive Fluid See page 83 80 MAINTENANCE ...

Page 83: ...earcase oil at the intervals outlined in the Periodic Maintenance Chart Maintain the oil level even with the bottom thread of the fill plug hole q Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications OIL CHECK The fill plug is located at the right rear of the vehicle To check the oil do the following 1 Position the vehicle on a level surface 2 ...

Page 84: ...the following 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 4 Reinstall the drain plug Torque to specification 5 Add the recommended oil as needed Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks Dispose ...

Page 85: ...he Gearcase Specifications Chart for recommended lubricants capacities and torque specifications OIL CHECK The front gearcase fill plug is located on the left side of the front gearcase To check the oil do the following 1 Position the vehicle on a level surface 2 Remove the fill plug q 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification 83 MA...

Page 86: ... securely with a jackstand 2 Remove the front tire on the driver s side 3 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 4 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 5 Reinstall the drain plug Torque to specification 6 Add the recommended oil as needed Do not overfill 7 Reinstall the fill plug Torque to speci...

Page 87: ...an result in loss of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal BRAKE INSPECTION WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper To inspect the brakes do the following 1 Check the brake...

Page 88: ...ere injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown To check the brake fluid level do the following 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 up...

Page 89: ...ng the adjustment cam either clockwise or counter clockwise to increase or decrease spring tension Always heed the following rules if you make adjustments to this suspension Always return the suspension to the lowest softest q setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the sa...

Page 90: ... damage or personal injury Always maintain proper tire pressure Always use POLARIS approved size and type of tires for this vehicle when replacing tires TIRE TREAD DEPTH Always replace tires when tread depth is worn to 3 mm 1 8 or less AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricat...

Page 91: ...N 1 Set the park brake 2 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin install...

Page 92: ...Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 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 wheel wells 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector ...

Page 93: ...e mark placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted BRAKE LIGHTS When the brake pedal is depressed the brake light comes on Check the brake light bef...

Page 94: ...the top of the light to remove the indicator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp Using a screwdriver rotate the lamp 1 4 turn clockwise to seat it 7 Snap the assembly back into the console panel Reconnect the har...

Page 95: ... conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water ...

Page 96: ...re the charging area is well ventilated 3 Make sure the key is off 4 Open the hood and any door enclosures or zippers 5 Always use a extension cord with a minimum rating of 20 amps 6 Inspect the charging cord and extension cord for cracks loose connections and frayed wiring Replace any damaged components promptly 7 Always connect the vehicle charger to the extension cord first then plug the cord i...

Page 97: ... Before removing the seat to access the batteries make sure any wire or metal items including seat belt latches remain clear of the battery compartment to avoid causing a short circuit to the electrical system BATTERY INSPECTIONS Inspect battery terminal connections monthly Clean batteries as recommended Using an insulated wrench torque bolts to 8 ft lbs 11 Nm BATTERY CLEANING Always keep battery ...

Page 98: ...cables Always see your dealer for battery related service BATTERY FLUID A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Add only distilled water Tap water contains minerals that are harmful to a battery Unless the plates are exposed before charging distilled water should be added to a battery after charging If the plates e are exposed add water to about 1 8...

Page 99: ...inse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots WASHING TIPS Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch th...

Page 100: ...el life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with ...

Page 101: ... Block the wheels to prevent rolling 9 Fully charge the batteries Leave the charger connected to maintain a full charge during the storage period or check battery voltage each month during storage and recharge as needed to maintain a full charge If the charger remains connected check it monthly to verify proper operation TIP Do not use plastic or coated materials They do not allow enough ventilati...

Page 102: ...RS Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation REMOVAL FROM STORAGE 1 Inspect all battery connections 2 Verify that batteries are fully charged 3 Verify that tire pressure is at specification 4 Perform the pre rid...

Page 103: ...3 cm Turning Radius 150 in 381 cm LOAD CAPACITY Box Dimensions Inside 32 x 42 x 11 5 in 81 x 107 x 29 cm Box Capacity 500 lbs 227 kg Payload Capacity 1000 lbs 455 kg Hitch Towing Capacity 1250 lbs 567 kg Cargo System Lock Ride Seating 2 Skid Plate Plastic PERFORMANCE Motor configuration Single 48 volt high efficiency AC induction motor Motor peak 30 HP Controller 650 Amp Sevcon Gen IV controller w...

Page 104: ... input 48 volt DC output Charge time 8 hours dependent on depth of discharge DRIVETRAIN Main gearcase transaxle Direct drive motor to transaxle with low noise gears Drive On demand AWD 2WD turf mode BRAKE SYSTEM Brakes 4 Wheel hydraulic disc w dual bore front calipers Park Brake Dash mounted lever activated mechanical park brake SUSPENSION Front suspension MACPHERSON Strut w 9 in 22 7 cm of travel...

Page 105: ...rge indicator Digital indicates battery discharge Hour meter Digital indicates cumulative hours of vehicle movement Auxiliary power 12 volt accessory outlet Rider restraints Automotive style 3 point seat belts Multi mode switch L M H Low Max Range High Headlights taillights brake lights Dual 50 watt Storage Glove box 103 SPECIFICATIONS ...

Page 106: ...104 ...

Page 107: ...freeze Coolant 1 qt 12 2880514 1 gal 6 2880513 Grease Gun Kit Premium All Season 2871312 All Season Grease Four 3 oz packs 6 2871322 14 oz cartridge 2871423 Premium Starter Grease 2871460 U Joint Grease 3 oz tube 24 2871515 14 oz cartridge 2871551 Dielectric Grease Nyogel 2871329 DOT 4 Brake Fluid 2872189 Loctite 565 Thread Sealant 2871956 POLARIS Battery Tender Charger 2859044 105 POLARIS PRODUCT...

Page 108: ...106 ...

Page 109: ...n codes will blink on the controller The code definitions provided here are for informational purposes only TIP If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault reversing direction without releasing the accelerator select neutral and turn the key off and on to clear the error If the error does not clear please see your POLARIS dealer for diagnos...

Page 110: ...tery pack not reaching required voltage charger output reduced due to high temperatures Check connections operate charger at lower ambient temperature 4 Battery could not be trickle charged to minimum voltage Check battery for shorted or damaged cells 5 Charger shut down due to overheating Ensure sufficient cooling air flow open the hood and reset the charger interrupt AC power for 15 seconds 6 Ch...

Page 111: ...rranty 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 for warranty No verification of registration will be sent to the purchaser as the copy of the Warrant...

Page 112: ... 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 113: ...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 114: ...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 115: ...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 116: ...ornia Air Resources Board and Polaris Industries Inc are 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...

Page 117: ...nt of time not to 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 ...

Page 118: ...116 ...

Page 119: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 117 MAINTENANCE LOG ...

Page 120: ...118 ...

Page 121: ...harging Cord 50 Chrome Wheel Care if equipped 98 Clean the Exterior 100 Clothing 13 Component Locations 35 Crossing Hillsides 27 D Descending Hills Improperly 27 Direction Selector Switch 38 Disengaging AWD 61 Drive Mode 60 Drive Mode Switch 40 Driving Downhill 57 Driving in Reverse 59 Driving on a Sidehill 58 Driving Through Water 58 Driving Uphill 57 Dumping the Cargo Box 63 E Exported Products ...

Page 122: ...peration Driving Over Obstacles 57 Driving with a Passenger 55 Slippery Surfaces 56 Operator Safety 21 P Park Brake Lever 46 Parking on an Incline 59 Parking the Vehicle 59 Part Numbers 105 Periodic Maintenance Chart 78 Polaris Products 105 Polishing the Vehicle 98 Poor Visibility 30 Pre Ride Inspection 52 Precautions During Maintenance 32 Proper Use Warning 15 Protective Apparel 24 R Registration...

Page 123: ...ing the Vehicle 66 Trail Etiquette 51 Transporting the Vehicle 65 Turning Improperly 27 U Unauthorized Use of the Vehicle 31 V Vehicle Identification Numbers 10 Ventilation When Charging Batteries 31 W Warning Symbols 8 Washing the Vehicle 97 Welcome Page 3 Wheel Installation 89 Wheel Removal 89 Winch Winch Operation 69 Winch Safety Precautions 67 Winch Cable Care 74 Winch Maintenance and Service ...

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Page 125: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9940321 Rev 02 Printed in USA ...

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Polaris RANGER EV 2022, Owner'S Manual

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