Polaris Ranger RZR Owner'S Manual For Maintenance And Safety Download Page 34 | Manualshive

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Polaris Ranger RZR Owner'S Manual For Maintenance And Safety Download Page 34

31

SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and is explosive under certain conditions.

Always exercise extreme caution whenever handling gasoline.
Always stop the engine when refueling.
Always refuel outdoors or in a well ventilated area.
Remove flammable material containers from the box before filling.
Do not smoke or allow open flames or sparks in or near the refueling area or

where gasoline is stored.
Never refuel while a person is in the vehicle.
Do not over fill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered

engine exhaust fumes are poisonous and can cause loss of consciousness

and death in a short time.

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Summary of Contents for Ranger RZR

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Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r 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 should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...n and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part ...

Page 6: ...hicle Identification Numbers 5 Safety 6 Features and Controls 32 Operation 54 Emission Control Systems 74 Maintenance 75 Specifications 126 Polaris Products 128 Troubleshooting 129 Warranty 133 Maintenance Log 137 Index 140 ...

Page 7: ... and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number ______________________________________________ Engine Serial Number ___________________________________________________ Key Number ____________________________________________________________ E...

Page 8: ... symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note wi...

Page 9: ...rry passengers in cargo box Maximum 4X4 Box Load is 300 lbs 136 4 kg Tire Pressure Cargo Overload Warning WARNING IMPROPER TIRES TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa 4X4 FRONT 8 55 2 REAR 8 55 2 MAXIMUM WEIGHT CAPACITY INCLUDING DRIVER PASSENGER CARGO AND ACCESSORIES 4X4 is 740 LBS 336 4 kg Reduce speed and allow greate...

Page 10: ...his vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 or without a valid driver s license Overturn Warning WARNING Improper operation can cause this vehicle to overturn and lead to serious injury or death This vehicle handles differently than cars trucks or other off road vehicles In order to avoid overturns av...

Page 11: ...oo small to firmly plant feet on the floor and securely grasp hand holds THE PASSENGER MUST ALWAYS wear seat belt use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on the floor tell operator to slow down or stop if uncomfortable get off and walk if conditions require keep hands and feet inside vehicle at all times watch for branches brush and other hazards ...

Page 12: ...rees on public roads on paved surfaces pavement may seriously affect handling and control with non Polaris approved accessories they may seriously affect stability ALWAYS keep hands and feet inside vehicle reduce speed and use extra caution when carrying a passenger operate slowly in reverse avoid sharp turns or sudden braking make sure passenger reads and understands all safety labels watch for b...

Page 13: ... more than one passenger Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels and has completed the New Opera tor Driving Procedures outlined on pages 60 61 To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns Never operate with accessories not approved by Polaris for use o...

Page 14: ... Always keep both hands on the steering wheel during operation A passenger should always be seated in the passenger seat with both feet on the floor and with both hands securely grasping the hand holds Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper proced...

Page 15: ...s may have reduced stopping ability To dry out the pads apply the brakes lightly several times while driving slowly 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 making sharp turns in reverse Always use the proper size and type of tires specified for your vehi cle Always maintain proper tire pres...

Page 16: ... to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers 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 vehicle WARNING Modifications to your vehicle may negatively impact vehicle stab...

Page 17: ... Riding Gear Always wear appropriate clothing when riding a Polaris vehicle Wear protective clothing for comfort and to reduce the chance of injury Helmet Eye Protection Gloves Sturdy Footwear Long Pants Long Sleeves ...

Page 18: ...ed 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 When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure p...

Page 19: ...As the operator of the vehicle you are responsible for your personal safety the safety of others including your passenger and the protec tion of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures We strongly advise you to strictly follow the recommended maintenance program outlined in you...

Page 20: ...ils 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 etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the ...

Page 21: ...RD Turning improperly WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts Practice turning at slow speeds...

Page 22: ...TO AVOID THE HAZARD Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor WARNING POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet and eye protection WHAT CAN HA...

Page 23: ...g WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD The operator should always keep both hands on the steering wheel during operation A passenger should securely grasp the hand holds and plant both feet firmly on the floor WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CA...

Page 24: ...nt resulting in serious injury or death HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNIN...

Page 25: ...e If unavoidable use extreme caution and operate slowly WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operating on slippery surfaces as described in the owner s manual When operating on slippery surfaces such as ice or loose gravel reduce speed and us...

Page 26: ...Never operate in fast flowing water or in water that exceeds the recommended maximum depth WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Collision with an obstacle or person resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operating in reverse as described in the owner s manual Before shifting into reverse gear always check ...

Page 27: ... exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death H...

Page 28: ... throttle suddenly Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the own...

Page 29: ...hill WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight...

Page 30: ...n resulting in serious injury or death HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD Operate at speeds appropriate for your skills the conditions and the terrain ...

Page 31: ...ing in serious injury or death HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death if the vehicle and or riders fall through the ice HOW TO AVOID THE HAZARD Never operate this vehicle on a frozen body of water ...

Page 32: ...nditions WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN Serious injury or death due to a fall from the vehicle or contact with moving components HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo box WARNING POTENTIAL HAZARD Operating with more than one passenger WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW ...

Page 33: ...s WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting...

Page 34: ...box before filling Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Never refuel while a person is in the vehicle Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered...

Page 35: ...d by both operator and passenger at all times Promptly replace worn or damaged cab nets with new cab nets available from your authorized Polaris dealer NOTE The vehicle illustrated below is shown without cab nets only to allow component identification Dash Hip Bar Fuel Tank Cap Seat Belts Cargo Box Seat Shifter Cab Frame Passenger Hand Hold Cab Nets ...

Page 36: ...33 FEATURES AND CONTROLS Component Locations Headlights Brush Guard Radiator Steering Wheel Storage Compartment under hood ...

Page 37: ...ehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 72 73 Taillights Receiver Hitch Muffler Spark Arrestor ...

Page 38: ...Loosen do not remove the four screws located on the seat bottom Slide the seat forward or rearward to the desired position Tighten the screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat 2 Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle Reverse this procedure to reinstall the seat Make sure t...

Page 39: ...table position for your passen ger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the mounting bracket hole through both post adjustment holes and through the remain...

Page 40: ...ve the fasteners 2 Grasp the upper hood edge and pull upward to disengage the hood from the vehicle 3 Continue pulling the hood upward to dis engage the lower hood fasteners 4 Lift the hood away from the vehicle Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gaso line with a minimum pump...

Page 41: ...side may interfere with vehicle opera tion for some operators due to operator body type driving style or riding apparel Each operator must check for upper cab net interference before operating the vehicle 1 Complete the New Operator Driving Procedures outlined on pages 60 61 2 Test for upper cab net interference by making slow speed turns to the left and right If the net interferes with operation ...

Page 42: ... the floor of the vehicle on the driver s side 2 Reinstall the lower net with the screw and all washers Tighten the screw securely 3 Unclip the four latches that secure the upper net to the chassis and lower net See the photo on the pre vious page 4 Clip the free upper latch of the lower cab net to the free latch on the shoulder net adjusting strap length as needed Tighten the strap 5 Reverse all ...

Page 43: ...ugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE Press the red release latch on the buckle to release the seat belt WARNING Riding in this vehicle without wearing the seat belt can result in serious injury or death in the event of an accident or sudden stop A...

Page 44: ...ust slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying dirt debris or stiffness If any damage is found have the seat belt system checked and or replaced by an authorized Polaris ...

Page 45: ...nd clock See page 49 for operation of the modes Work Light Switch Use the work light switch to turn the work light on or off The work light is located at the rear of the vehicle Turn the light on while loading and unloading cargo in low light situations Turn the work light off when driving Light Switch AWD Switch 12V Accessory Outlet Mode Switch Ignition Switch Instrument Cluster Work Light Switch...

Page 46: ... Press the bottom of the switch to operate in two wheel drive See page 46 for AWD operating instructions Auxiliary Outlet The 12 volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are under the dash WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle r...

Page 47: ... transmission function See your dealer if you experience any shifting problems Using Low Range and High Range CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Operating in rough terrain or...

Page 48: ...ttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before start ing the engine Make sure there s adequate throttle pedal freeplay See page 104 for throttle pedal adjustment procedures Throttle Pedal Brake Pedal ...

Page 49: ... in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AW...

Page 50: ...t senses vehicle speed from the transmission The instrument cluster measures distance in miles as well as time hours of operation and engine RPM NOTE In addition to showing vehicle speed the speedometer needle flashes when the fuel level is low Rider Information Center Speedometer Speedometer Needle ...

Page 51: ...ic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge Th...

Page 52: ...eset the trip meter select the trip meter mode Press and hold the mode switch until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations...

Page 53: ...ated 4 Use the mode switch to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode Toggle to the clock screen 2 Press and hold the mode switch until the hour display flashes Release the switch 3 Press and release the mode switch once to advance the setting by one hour Press and hold the mode switch to advance the hours quickly 4 When the desired hour is...

Page 54: ...it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory To enable or disable the service interval 1 Enter the diagnostic mode Toggle to the service interval screen 2 Press and hold the mode switch for about seven 7 seconds until either ON or OFF appears in the Rider Information Center depend ing on your preference To reset the ...

Page 55: ...ng the mode has been set Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 53 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the ke...

Page 56: ...ircuit to Ground 51 Injector 1 Short Circuit to Battery 52 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Battery 56 Pump Relay Open Load 56...

Page 57: ...ents will result in more efficient performance and longer life for these components Per form the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any oils other than those recommended by Polaris ...

Page 58: ...rform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 56 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours or one month Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pa...

Page 59: ...ct ensure fastener tightness 109 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 48 83 Coolant level Ensure proper level 97 98 Coolant hoses Inspect for leaks Throttle Ensure proper operation 103 Indicator lights switches Ensure proper operation 43 Air filter pre filter Inspect clean 101 Headlamp Check operation apply Polaris dielec tric grease when lamp is re...

Page 60: ...ts 6 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmission in PARK 3 Turn the engine off WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in a...

Page 61: ... re familiar with the controls NOTE When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine braking WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo ...

Page 62: ...s extremely flammable and can be explosive under certain conditions 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 WARNING A rolling vehicle can cause property damage and serious injury Always place the transmission in PARK when stopping the en...

Page 63: ...of travel 4 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving WARNING Operating improperly can cause an accident or overturn which could result in severe injury or death This vehicle handles differently than cars trucks or other off road vehicles Operators of this vehicle must become familiar with vehicle handling at s...

Page 64: ...w speed 6 Check for upper cab net interference See page 39 7 Increase speed only after mastering all maneuvers at a slow speed 8 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the te...

Page 65: ... least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured put both feet on the floor and grasp the hand holds 4 Make sure the passenger is wearing appropriate riding gear includ ing an approved helmet and eye protection See page 14 5 Make sure the passenger secures the seat belt 6 Make sure all cab nets are properly secured ...

Page 66: ...ontrols 9 Slow down Always travel at a speed appropriate for your skills your passenger s skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 10 Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 11 Always follow all operating guidelines as outlined on safety labels an...

Page 67: ...eels begin to lose traction 4 Correct a skid by turning the steering wheel in the direction of the skid CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control a...

Page 68: ...l speed WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper operating procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating...

Page 69: ...s as if it may overturn immediately turn downhill 4 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 5 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and care fully until the vehicle can be driven straight downhill WARNING Crossing hillsides or turning on...

Page 70: ...ghtly to aid in slowing WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the v...

Page 71: ...he ser vices outlined in the Periodic Maintenance Chart beginning on page 75 Give special attention to engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 113 and take the vehicle to your dealer at the first opportunity WARNING The large tires ...

Page 72: ...over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and operate slowly 4 Always have a passenger dismount and move away from the vehicle before operating over an obstacle that could cause an overturn WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and...

Page 73: ...ightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid making sharp turns ...

Page 74: ...sion in PARK 2 Turn the engine off 3 Block the rear wheels on the downhill side WARNING A rolling vehicle can cause property damage and serious injury Always place the transmission in PARK when stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead ...

Page 75: ... 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 situations that may require backing downhill USE EXTREME CAUTION w...

Page 76: ... or towing heavy cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when towing Never load more than 150 lbs 68 1 kg tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing Towing a trailer increases brakin...

Page 77: ...R 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled ...

Page 78: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style hi...

Page 79: ...ted service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 80: ...em Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed Coolant if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed X Q Brake pad wear 10 H M...

Page 81: ...ke ducts flange 50 H 6 M 300 500 Inspect duct for proper seal ing air leaks X General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust Q Steering 50 H 6 M 500 800 Lubricate X Front Suspension 50 H 6 M 500 800 Lubricate X Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system if applicable 50 H 6 M 500 800 Inspect coola...

Page 82: ...aust muffler pipe 100 H 12 M 1000 1600 Inspect Q Ignition timing 100 H 12 M 1000 1600 Inspect X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspect replace as needed Q Front wheel bearings 100 H 12 M 100...

Page 83: ...es See page 106 Transmission Oil Main Gearcase Premium AGL Synthetic Gearcase Lube See page 88 Transmission Oil Transfer Case Premium AGL Synthetic Gearcase Lube See page 86 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid See page 90 Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 91 Prop Shaft Polaris Premium U Joint Lube Locate fittings and grease Control Arm Pivot Bushi...

Page 84: ...81 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings ...

Page 85: ...o 49 C Its exceptional frictional properties result in more efficient operation more power out put and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient...

Page 86: ...ts Remove the rear service panel See page 35 5 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely but do not lock it The dipstick must be inserted completely in to keep the angle and depth of the stick consistent 7 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Due to the dipstick ...

Page 87: ...y 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 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Reinstall the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinst...

Page 88: ...dition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the dipstick and fill the sump with two quarts 1 9 l of rec ommended oil 13 Place the transmission in PARK Apply the brakes 14 Start the engine Allow it to idle for one to two minutes 15 Stop the engine Inspect for leaks 16 Re check the oil level on the...

Page 89: ...ug and level check plug are located on the left side of the transfer case The fluid level is sufficient when fluid flows out of the check plug hole at step 4 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Remove the level check plug 4 Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole 5 Reinstall the level check plug Torque to spe...

Page 90: ...ug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Remove the level check plug 7 Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole 8 Reinstall the level check plug Torque to specification 9 Reinstall the fill plug Torque to specification 10 Chec...

Page 91: ...ons Chart on page 92 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the left side of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid as needed 5 Reinstall the fill plug Torque to specification Fill Pl...

Page 92: ...ug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque to specification 6 Add the recommended fluid to the fill hole Maintain the fluid level at the bottom of the fill plug hole Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Discard used fluid properly Transfer Case Drain Plug Re...

Page 93: ...a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug If the o ring is damaged install a ...

Page 94: ...surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the rear gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug 3 Allow the fluid to drain completely 4 Clean the drain plug Reinstall the drain plug wi...

Page 95: ...e Transmission Main Gearcase Premium AGL Synthetic Gearcase Fluid 24 oz 710 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Transmission Transfer Case Premium AGL Synthetic Gearcase Fluid 14 oz 414 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Demand Drive Unit Front Gearcase Demand Drive LT Premium Fluid 6 75 oz 200 ml 8 10 ft lbs 11 13 6 Nm 11 ft lbs 15 Nm Rear Gearcase Premium ATV Angle Drive Fluid...

Page 96: ...park plug for correct color See page 94 CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 126 Model Electrode Gap New Plug Torque Used Plug Torque RANGER RZR 035 9 mm 18 ft lbs 24 Nm 18 ft lbs 24 Nm WARNING A hot exhaust system and engine can cause serious burns Wear protect...

Page 97: ...t 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 injection oil or incorrect throttle body adjust ments Spark Plug Removal and Replacement 1 Remove both seats 2 Remove the rear service panel See page 35 3 R...

Page 98: ... as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible a...

Page 99: ...uct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommend...

Page 100: ...Position the vehicle on a level surface 2 Remove the hood See page 37 3 View the coolant level in the overflow bottle 4 If the coolant level is below the safe operating range remove the cap and use a funnel to add coolant through the opening Reinstall the cap NOTE If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system ...

Page 101: ... See page 37 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected NOTE Use of a non standard pressure cap will not allow the recove...

Page 102: ...h 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 PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibi...

Page 103: ...e water to drain 4 Tighten the screws 5 Place the transmission in PARK Apply the brakes 6 Start the engine 7 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 8 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 9 Test for belt s...

Page 104: ...dge 3 Remove the air filter 4 Remove the pre filter from the main air filter 5 Wash the pre filter in soapy water then rinse and let dry NOTE Install a new main filter if needed Do not attempt to clean the main air filter 6 Reinstall the pre filter over the main filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 7 Inspect the air box for...

Page 105: ...install the arrestor Torque screws to 5 7 ft lbs 7 9 Nm WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before pro...

Page 106: ...tion 1 Place the transmission in PARK 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle p...

Page 107: ...ttle cable adjuster 3 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 103 NOTE While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the ru...

Page 108: ...dicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 106 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs WARNING Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an accident resu...

Page 109: ... the transmission in PARK 3 View the brake fluid level in the reservoir The level should be between the maxi mum and minimum level lines 4 If the fluid level is lower than the lower level line add brake fluid to the upper line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING After opening a bottle of brake fluid always discard any unused portio...

Page 110: ... 64 1 mm Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough o...

Page 111: ...hicle slightly for easier adjustment Always heed the following rules if you make adjustments to this suspen sion Always return the suspension to the lowest softest 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 same adjustment setting to all four wheels Never operate the vehi...

Page 112: ...esult in serious injury or death Always replace tires when the tread depth measures 1 8 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 When replacing tires always use original equipment size and type Wheel Type Nut Type Location N...

Page 113: ...he correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward for ward rotation 3 Attach the wheel nuts and washers and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 109 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can resu...

Page 114: ...e lamp counter clockwise to remove it 3 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 4 Reinstall the harness assembly into the head light assembly WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot compo...

Page 115: ...n 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 8 20 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 If adjustment is necessary turn the headlight adjustment screw to adjust the beam 6 Repeat step...

Page 116: ...f water is present dry the air box and replace the filter with a new filter Thoroughly dry the air pre filter See page 101 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs NOTE Attempt to start the engine If necessary repeat the drying procedure 6 Take the vehicle to your dealer for service as soon as possible whether you s...

Page 117: ...an 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 WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magne...

Page 118: ...o tip a conven tional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last CAUTION If electrolyte spills immediately wash it off with...

Page 119: ...e a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 8 Reinstall the dri...

Page 120: ...ttery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 128 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the b...

Page 121: ...e 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 For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A f...

Page 122: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 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...

Page 123: ...ith 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 the finish CAUTION High water pressure may damage c...

Page 124: ...ontact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishi...

Page 125: ...ent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pr...

Page 126: ...r to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 84 Air Filter Air Box Inspect and clean or replace the pre filter and air filter See page 101 Clean the air box Drain the sediment tube Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 75 Demand drive fluid front gearca...

Page 127: ...avities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 94 4 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a prot...

Page 128: ...uld be checked by an authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seats 4 Always tie the frame of the Polaris vehicle t...

Page 129: ... kg riders cargo accessories Receiver Hitch Tongue Capacity 150 lbs 68 kg Receiver Hitch Towing Capacity 1500 lbs 680 kg Overall Length 102 in 259 cm Overall Width 50 in 127 cm Overall Height 68 5 in 174 cm Wheelbase 77 in 196 cm Ground Clearance 10 in 25 4 cm Engine 4 valve 4 stroke twin cylinder with counterbalance Displacement 760 cc Bore x Stroke 80mm x 76mm Alternator Output 500 W 3000 RPM Co...

Page 130: ... Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Tire Size Front 25 x 8 12 Tire Size Rear 25 x 10 12 Tire Pressure Front 8 psi 55 KPa Tire Pressure Rear 8 psi 55 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 single beam 55W quartz halogen Taillights 2 single beam 5W Brake Lights 2 single beam 5W Instru...

Page 131: ...465 Pump for Gallon Jug 2876251 Demand Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint...

Page 132: ...smission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from 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 o...

Page 133: ...ed fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark ...

Page 134: ...t range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge 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 Other mechanical failure See your dealer Possible Lea...

Page 135: ... Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clea...

Page 136: ...hat are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer ...

Page 137: ...ests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state...

Page 138: ...o an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form 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 coun...

Page 139: ...or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TOR...

Page 140: ...137 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 141: ...138 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 142: ...139 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 143: ... 38 39 Cap Fuel 37 Cargo 72 73 Changing Coolant 95 Changing Gears 44 Chart Periodic Maintenance 75 79 Chrome Wheel Care 122 Cleaning and Storage 120 125 Cleaning the Air Filter 101 Cleaning the Exhaust System 102 Cleaning the Spark Arrestor 102 Clock Setting 50 Clothing 15 Component Locations 32 34 Condition Spark Plugs 94 Coolant Level 97 Coolant Level Radiator 98 Coolant Adding or Changing 95 Co...

Page 144: ...ransfer Case 87 Transmission 89 Fluid Check Demand Drive 90 Front Gearcase 90 Main Gearcase 88 Transfer Case 86 Transmission 88 F Fluid Levels During Storage 123 Fluid Recommendations Gearcase 92 Fluid Battery 117 Fluid Brake 106 Fogging the Engine 124 Fouled Plugs 94 Freeplay Adjustment Throttle 104 Freeplay Steering Wheel 107 Freeplay Throttle 103 Fuel Cap 37 Fuel Safety 31 Fuel Stabilizer 123 F...

Page 145: ...2 85 Front Gearcase 90 Main Gearcase 88 89 Rear Gearcase 91 Transfer Case 86 87 Transmission 88 89 O Oil and Filter Care During Storage 123 Oil Change Demand Drive 90 Engine 85 Engine Oil 84 Front Gearcase 90 Main Gearcase 89 Rear Gearcase 91 Transfer Case 87 Transmission 89 Oil Check Demand Drive 90 Engine Oil 83 Front Gearcase 90 Main Gearcase 88 Transfer Case 86 Transmission 88 Operation on Pub...

Page 146: ...Front 37 Storage 120 125 Battery 117 Covers 124 Fluid Levels 123 Inspections 124 Lubrication 124 Oil and Filter 123 Removal 125 Storage Area 124 S Suspension Adjustment 108 Switches 42 43 AWD Switch 43 46 Ignition Switch 43 Light Switch 43 Mode Switch 42 Work Light Switch 42 T Tachometer 49 50 Throttle Freeplay Adjustment 104 Throttle Freeplay Inspection 103 Throttle Freeplay 103 Throttle Pedal 45...

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