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Table of Contents
Related Manuals for Polaris RANGER XP 4X4 700 EFI
Summary of Contents for Polaris RANGER XP 4X4 700 EFI
- Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
- Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
- Page 5 Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
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Page 6: Table Of Contents
......EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION POLARIS PRODUCTS SPECIFICATIONS TROUBLESHOOTING WARRANTY . -
Page 7: Vehicle Identification Numbers
Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. -
Page 8: Safety
Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. -
Page 9: Operator Safety
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. - Page 10 Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully. Follow the operating pro- cedures described.
- Page 11 Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. S Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate this vehicle on hills too steep for the vehicle or for your abilities.
- Page 12 Gasoline is extremely flammable. See page 22 for refueling instruc- tions. S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764. SAFETY...
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Page 13: Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. - Page 14 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped.
- Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control 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.
- Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.
- Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts...
- Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it’s in safe operating condition.
- Page 19 WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris RANGER. Even though a child may be within the age group for which some...
- Page 20 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
- Page 21 RANGER, always read and follow the instructions of the decals on the RANGER. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
- Page 22 Safety Decals and Locations S VEHICLE ROLLOVER could cause severe injury or death. This cab frame is not designed or intended to provide rollover protection. S ALWAYS WEAR YOUR SEAT BELT for maximum protection. Location 2 Location 3 (inside front of box) Container/Passenger/Tire Pressure Warning Decal Text Remove flammable material containers from box before filling.
- Page 23 SAFETY Safety Decals and Locations Location 5 (under hood) S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.
- Page 24 SAFETY Safety Decals and Locations Discretionary Warning Decal...
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Page 25: Fuel Safety
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. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored. -
Page 26: Features And Controls
FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 100. Component Locations 1. Cab Frame (if equipped) 2. Hip Bar 3. -
Page 27: Component Locations
FEATURES AND CONTROLS Component Locations 12. Headlights 13. Radiator (if equipped) 14. Front Bumper/Brush Guard 15. Hood Hold Down Strap... - Page 28 FEATURES AND CONTROLS Component Locations 16. Taillights 17. Tailgate 18. Tailgate Latch Release 19. Muffler (Spark Arrester) 20. CV Boot/Rear Caliper 21. Air Box 22. Receiver Hitch...
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Page 29: Indicator Lights
FEATURES AND CONTROLS Indicator Lights 1. High Gear 2. Low Gear 3. Neutral Gear 4. Reverse Gear 5. High Temperature 6. Park Brake Trailer Hitch Bracket This vehicle 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 page 48. -
Page 30: Seat Removal
FEATURES AND CONTROLS Fuel Cap/Fuel Gauge The fuel tank filler cap (8) is located on the right-hand side of the vehicle near the passenger seat. It has a built-in fuel gauge that indicates the amount of fuel remaining in the tank. When the indicator needle nears the E (empty) mark, refuel at the earliest opportunity. -
Page 31: Seat Belts
FEATURES AND CONTROLS Seat Belts The RANGER is equipped with lap-style seat belts for the operator and passenger. 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 RANGER. - Page 32 Console 1. Cup Holder 2. Indicator Lights 3. Shift Lever 4. Light Switch 5. AWD/Differential Switch (if equipped) 6. Hour Meter 7. Glove Box with Lid 8. 12V Accessory Plug 9. Storage Tray 10. Ignition Switch 11. Storage Box FEATURES AND CONTROLS...
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Page 33: Gear Selector
FEATURES AND CONTROLS Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for the RANGER XP. High gear is intended for use on hard-packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. -
Page 34: Ignition Switch
Switches Ignition Switch (1) The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Engine off. All electrical circuits are off except Acc. 12V. ON/RUN Electrical circuits are on. Electrical equipment can be used. -
Page 35: Brake Pedal
FEATURES AND CONTROLS Brake Pedal (1) Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal (2) Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. -
Page 36: Operation
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 22. 2. Check the oil level on the dipstick. See page 61. Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal (safe) operating range. - Page 37 Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Page 86,101...
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Page 38: Starting The Engine
Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Sit in the driver’s seat and fasten the seat belt. 2. -
Page 39: Stopping The Engine
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Engage the park brake. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. Braking 1. -
Page 40: Driving Safely
Driving Safely Driving Procedures 1. Sit in the driver’s seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the service brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. -
Page 41: Driving On Slippery Surfaces
OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2. -
Page 42: Driving Uphill
Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15_ maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn. -
Page 43: Driving Downhill
OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15_ maximum). -
Page 44: Driving Through Water
Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1). -
Page 45: Driving Over Obstacles
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. -
Page 46: Driving In Reverse
Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. -
Page 47: Parking On An Incline
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury. -
Page 48: Hauling Cargo
Driving Safely Hauling Cargo WARNING Hauling cargo 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 hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. - Page 49 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. RANGER 4X4 XP RANGER 6X6 EFI WARNING Driving with passengers in the cargo box can result...
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Page 50: Dumping The Cargo Box
Driving Safely Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. -
Page 51: Towing Loads
OPERATION Driving Safely 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. -
Page 52: Parking The Ranger
Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. Turn the engine off. 3. Engage the park brake. 4. - Page 53 OPERATION Differential Lock (4X4) The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. It’s beneficial to lock the differential in low traction situations. Move the AWD/Differential Lock rocker switch to the center position (A) to lock the differential and return to 2WD.
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Page 54: All Wheel Drive (Awd)
All Wheel Drive (AWD) The illuminated amber AWD switch (1) indicates that the vehicle is in AWD. When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage. -
Page 55: Emission Control Systems
CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. -
Page 56: Maintenance And Lubrication
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 116. -
Page 57: Periodic Maintenance Chart
Perform these procedures more frequently for vehicles subjected to " severe use. Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. - Page 58 25 H " Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride...
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Page 59: Maintenance Interval
100 H " Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 25 H... - Page 60 Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M...
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Page 61: Lubrication Recommendations
More often under severe use, such as wet or dusty conditions " Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. - Page 62 MAINTENANCE AND LUBRICATION Lubrication Recommendations...
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Page 63: Engine Oil
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. -
Page 64: Oil Check
Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil dipstick and fill tube (1) is located on the engine. - Page 65 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.
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Page 66: Gearcase Specification Chart
MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 12. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil. 13. Shift the transmission to neutral. 14. Engage the park brake. 15. Apply the brakes. Start the engine. Allow it to idle for one to two minutes. - Page 67 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. 2. Remove the fill plug.
- Page 68 MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Oil Change The drain plug (2) is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug.
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Page 69: Front Gearcase
The front gearcase fill plug (1) is located on the right side of the front gearcase. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. - Page 70 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. The middle gearcase fill plug (1) is located on the side of the gearcase.
- Page 71 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products. The rear gearcase fill plug (1) is on the driver’s side of the rear gearcase.
- Page 72 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan under the drain plug (2). Remove the drain plug. 3. Drain the oil. Dispose of used oil properly. 4. Clean the drain plug. Reinstall the drain plug. Torque to specification.
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Page 73: Spark Plugs
MAINTENANCE AND LUBRICATION Spark Plugs 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 100. Spark Plug Gap/Torque Model Electrode Gap RANGER .035″ (.9 mm) - Page 74 MAINTENANCE AND LUBRICATION Spark Plugs 2. Wet Fouled 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 adjustments.
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Page 75: Cooling System
Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 99 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations... -
Page 76: Coolant Level
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 inspected by your Polaris dealer. -
Page 77: Radiator Coolant Level
MAINTENANCE AND LUBRICATION Cooling System Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. -
Page 78: Low Range
MAINTENANCE AND LUBRICATION Polaris Variable Transmission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.). -
Page 79: Pvt System
Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during... -
Page 80: Pvt Drying
MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Loosen the bottom screws that secure the clutch cover. 2. -
Page 81: Air Filter
Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter. -
Page 82: Spark Arrestor
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. -
Page 83: Throttle System
MAINTENANCE AND LUBRICATION Throttle System 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 pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. - Page 84 3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of adjuster. Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment.
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Page 85: Brake Fluid
MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 32. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation. -
Page 86: Brake Inspection
MAINTENANCE AND LUBRICATION Brakes Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear. -
Page 87: Steering Wheel Inspection
4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized Polaris dealer. Suspension Adjustment (4X4) The 4X4 rear suspension may be adjusted to provide a stiffer suspension if necessary. - Page 88 3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driving.
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Page 89: Tire Tread Depth
MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result 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. -
Page 90: Wheel Installation
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park brake. -
Page 91: Headlight Lamp Replacement
MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. -
Page 92: Headlight Beam Adjustment
MAINTENANCE AND LUBRICATION Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. -
Page 93: Tool Kit
MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the console panel. -
Page 94: Vehicle Immersion
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your RANGER to a dealer before starting it, follow the steps outlined below. - Page 95 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
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Page 96: Battery Removal
MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery. -
Page 97: Battery Installation
MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. - Page 98 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 99 for the part numbers of Polaris products. Cleaning the RANGER Keeping your RANGER clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your RANGER can be cleaned much like an automobile.
- Page 99 Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation...
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Page 100: Battery Maintenance
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 protective film of fresh oil. 6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Battery Maintenance Remove the battery and recharge it fully. -
Page 101: Removal From Storage
4. Check all the points listed in the Daily Pre-Ride Inspection section on page 34. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. -
Page 102: Polaris Products
60/40 Coolant (gal.) 2871323 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS... -
Page 103: Specifications
SPECIFICATIONS Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. - Page 104 Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for clutching specifications. SPECIFICATIONS RANGER 4X4 XP Pressurized Wet Sump 0W/40 PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R) 8.71:1...
- Page 105 SPECIFICATIONS Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Min. Turning Radius Cargo Box (L x W x H) Engine Displacement Bore x Stroke...
- Page 106 Brakes, Front/Rear Brake, Parking Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for clutching specifications. SPECIFICATIONS RANGER 6X6 EFI MacPherson strut w/6.25 in. (15.9 cm) of travel Independent w/5.25 in. (13.3 cm) of travel Swing arm w/dual shocks w/6.25 in.
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Page 107: Troubleshooting
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Engine Turns Over, Fails to Start... - Page 108 TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
- Page 109 Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.5 VDC Replace with recommended fuel...
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Page 110: Warranty
WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma- terial 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... - Page 111 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
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Page 112: How To Get Service
How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice... - Page 113 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
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Page 114: California Emission Control Warranty Statement
Your emission control system includes parts such as the carburetor and the ignition sys- tem. Also included may be hoses, connectors and other emission-related assemblies. Where a warrantable condition exists, POLARIS will repair your LSI engine at no cost to you, including diagnosis, parts and labor. -
Page 115: Warranty Period
Owner’s Safety and Maintenance Manual (herein “Own- er’s Manual”). POLARIS recommends that you retain all receipts covering mainten- ance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. - Page 116 California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold start enrichment system, if applicable. (iv) Regulator assy (gaseous fuel, if applicable) (2) Air Induction System (i) Intake manifold, if applicable...
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Page 117: Maintenance Schedule
When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience. - Page 118 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed.
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Page 119: Maintenance Log
MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS... - Page 120 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
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Page 121: Index
INDEX Age Restrictions ....Air Filter ..... . All Wheel Drive (AWD) . - Page 122 Parking the RANGER ... . Periodic Maintenance Chart Polaris Products ....Pre Ride Inspection ....