7SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d
97MAINTENANCE AND LUBRICATIO NRemoval from Storage1. Check the battery electrolyte level and charge the battery ifnecessary. Install it in the vehicle
98MAINTENANCE AND LUBRICATIO NBatteryKeep the battery terminals and connections free of corrosion. Ifcleaning is necessary, remove the corrosion with
99MAINTENANCE AND LUBRICATIO NBatteryReplenishing Battery Fluid (Conventional Battery)A poorly maintained battery will deterioraterapidly. Check the b
100MAINTENANCE AND LUBRICATIO NBatteryBattery Installation1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obst
101POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.
102SPECIFICATIONSRANGER TMGross Vehicle Weight 2400 lbs. (1089 kg)Fuel Capacity 8.5 gal. (32.2 l)Towing Capa city 1000 lbs. (454 kg)Max. Cargo Box Loa
103SPECIFICATIONSRANGER TMLubrication System Full PressureEngine Oil 0W/40Driving System Type PVTShift Type Single Lever (console)Gear Reduct ion - Lo
104SPECIFICATIONSRANGER 2x4Gross Vehicle Weight 2500 lbs. (1135 kg)Fuel Capacity 8.5 gal. (32.2 l)Towing Capa city 1400 lbs. (636 kg)Max. Cargo Box Lo
105SPECIFICATIONSRANGER 2x4Lubrication System Dry SumpEngine Oil 0W/40Driving System Type PVTShift Type Single Lever (console)Gear Reduct ion - Low 8.
106SPECIFICATIONSRANGER 4X4Gross Vehicle Weight 2700 lbs. (1226 kg)Fuel Capacity 8.5 gal. (32.2 l)Towing Capa city 1500 lbs. (681 kg)Max. Cargo Box Lo
8SAFETYOperator SafetyS Always follow proper procedures for turning as described in thismanual. Practice turning at slow speeds before attempting t o
107SPECIFICATIONSRANGER 4X4Lubrication System Dry SumpEngine Oil 0W/40Driving System Type PVTShift Type Single Lever (console)Gear Reduct ion - Low 8.
108TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Turn OverPos
109TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap
110TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel RefuelKinked or plugged fuel vent line Inspect and replaceWater presen
111WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris
112WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND F
113WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NOWARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT ISSOLD O
114WARRANTYCalifornia Emission Control Warranty StatementYour Warranty Rights and ObligationsThe California Air Resources Board and Polaris Industries
115WARRANTYCalifornia Emission Control Warranty StatementWarranty PeriodThis warranty period begins on the date, which the LSI engine is delivered, to
116WARRANTYCalifornia Emission Control Warranty StatementWhat is Not Covered Under This WarrantyThis warranty does not cover any emission-related part
9SAFETYOperator SafetyS Never modify this vehicle through improper installation or use ofaccessories.S Never exceed the stated load capacity for this
117WARRANTYCalifornia Emission Control Warranty StatementMaintenance ScheduleItem Maintenance Interval(whichever comes first)RemarksHours Calendar Mil
118WARRANTYCalifornia Emission Control Warranty StatementRepair and Replacement of Emission-Related PartsIt is recommended that only LSI engine replac
119WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limitedwarranty is in addi
120MAINTENANCE LOGPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / CO
121MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
122INDEXAAge Restrictions 5...Air Filter (2x4, 4X4) 78...Air Filter (TM) 80...All Wheel Drive (AWD) 49 -50...
123INDEXNNoise Emission Control System 5 2...OOil and Filter Change (2x4, 4X4) 62-63.Oil and Filter Change (TM) 66-67...Oil Check (2x4, 4X4) 61...
10SAFETYOperator SafetyWARNINGMake sure your RANGER is in excellent operating condition at alltimes. We strongly recommend that the operator check all
11SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards whileclimbing a hillWHAT CANHAPPENVehicle overturnHOW TO AVOID THEHAZARDMain
12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfacesWHAT CANHAPPENLoss of controlHOW TO AVOID THEHAZARDThis vehicle’
13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads or highwaysWHAT CANHAPPENCollision with another vehicleH
14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle at excessive speedsWHAT CANHAPPENLoss of control, accidentHOW TO AVOID THEHAZARDA
15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to inspect the vehicle before operatingFailure to properly maintain the vehicleWHAT CANHAPPENAcc
16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to follow the minimum age recommendations for thisvehicleWHAT CANHAPPENSerious injury or death (
17SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always
18SAFETYSafety Decals and LocationsWarning decals have been placed on the RANGER for your protection.Read and follow the instructions of the decals on
19SAFETYSafety Decals and LocationsFuel / Passenger Warning Decal TextRemove flammable containers from box before refueling.S Passengers can be thrown
20SAFETYSafety Decals and LocationsMANUFACTUREDBY: POLARIS IND INC.DATE:VIN:THIS VEHICLE IS A GENERAL PURPOSE OFF-ROADUTILITY VEHICLE AND IS NOT INTEN
21SAFETYSafety Decals and LocationsDiscretionary Warning DecalImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER:S Operate on public road
22SAFETYFuel SafetyWARNINGGasoline is highly flammable and is explosive under certainconditions. Always exercise extreme caution whenever handlinggaso
23FEATURES AND CONTROLSSome Polaris vehicles are equipped with special features such as thecab frame. Not all models come with all features. Refer to
24FEATURES AND CONTROLSComponent Locations10. Headlights11. Radiator (if equipped)12. Front Bumper/Brush Guard13. Hood Hold Down Strap12111013
25FEATURES AND CONTROLSComponent Locations14. Taillights15. Tailgate16. Tailgate Latch Release17. Muffler (Spark Arrester)18. CV Boot/Rear Caliper19.
26FEATURES AND CONTROLSIndicator LightsThe indicator lights on the console display:1. High Gear2. Low Gear (if equipped)3. Neutral Gear4. Reverse Gear
The engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.WARNING
27FEATURES AND CONTROLSSeat RemovalPull up on the front of the seatand slide it toward the front ofthe vehicle.Install the seat by sliding t hetabs in
28FEATURES AND CONTROLSConsole1. Cup Holder2. Indicator Lights3. Shift Lever4. Light S witch5. AWD/Differential Switch (if equipped)6. Hour Meter7. Gl
HLNRHNR29FEATURES AND CONTROLSGear Selector (1)RANGER 2X4, 4X4H: High GearL: Low GearN: NeutralR: ReverseRANGER TMH: High GearN: NeutralR: ReverseNOTE
12AWDDEF2WDABC4330FEATURES AND CONTROLSIgnition Switch (1)The ignition switch is a three-position, key-operated switch. The keycan be removed from the
123431FEATURES AND CONTROLSBrake Pedal (1)Depress the brake pedal to slow or stop the vehicle.Throttle Pedal (2)Push the pedal down to increaseengine
32OPERATIONVehicle Break-In PeriodThe break-in period for your new Polaris RANGER is the first twentyhours of operation, or the time it takes to use t
33OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl
123434OPERATIONStarting the EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness resulting in severe inju
35OPERATIONStarting the EngineStarting a Warm EngineWarm engines do not normally require the use of the choke. Overuse ofthe choke can cause the spark
36OPERATIONBraking1. Release the throttle pedal completely.2. Press on the brake pedal evenly and firmly.NOTE: Practice starting and stopping (using t
1WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wi de family of Polaris owners. We proudly produce an excitingline of uti
37OPERATIONDriving SafelyDriving Procedu res1. Sit in the driver’s seat and fasten the seat belt.2. After starting the engine and allowing it to warm
38OPERATIONDriving SafelyDriving On Slippery SurfacesWhen driving on slippery surfaces such as wet trails, loose gravel, orice, be alert for the possi
39OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15_
40OPERATIONDriving SafelySidehillingWARNINGCrossing hillsides or turning on hills can result in loss of control orvehicle overturn, resulting in sever
141OPERATIONDriving SafelyDriving Through WaterWARNINGThe large tires on your RANGER may cause the vehicle to float indeep or fast-flowing water, whic
42OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Watch for hazards such as logs,
43OPERATIONDriving SafelyDriving in ReverseFollow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3
44OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Place the t ransmi
45OPERATIONHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and maycause loss of control or brake instability, which can result
46OPERATIONHauling CargoDumping th e Cargo BoxWARNINGOperating the vehicle while the cargo box is raised could result insevere injury. The box could c
2Copyright 2005 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat
47OPERATIONHauling CargoTowing LoadsWARNINGTowing improperly can alter vehicle handling and may cause lossof control or brake instability, which can r
48OPERATIONDriving SafelyParking the RANGERWARNINGA rolling vehicle can cause property damage and serious injury.Always apply the parking brake after
AWD2WDAWD2WD49OPERATIONDifferential Operation ModesThe rear axle is equipped with a lockable differential. On AWDmodels, engaging AWD locks the front
50OPERATIONAll Wheel Drive (AWD)When in AWD, the front gearcase will automatically engage anytimethe rear wheels lose traction. When the rear wheels r
51EMISSION CONTROL SYSTEMSCrankcase Emission Control SystemThis engine is equipped with a closed crankcase system. Blow-bygases are forced back to the
52EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with U
53MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition
54MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartMaintenance Chart Key" Perform these procedures more frequently for vehicles subjected to
55MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Inter
56MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"EEngine b
3TABLE O F CONTENTSVEHICLE IDENTIFICATION NUMBERS 4...SAFETY 5...FEATURES AND CONTROLS 23...OPERATION
57MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)JEFuel system 1
58MAINTENANCE AND LUBRICATIO NLubrication RecommendationsCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart
59MAINTENANCE AND LUBRICATIO NLubrication Recommendations(1)(2)TM4X4TM
60MAINTENANCE AND LUBRICATIO NEngine OilAlways check and change the engine oil at the intervals outlined in thePeriodic Maintenance Chart beginning on
161MAINTENANCE AND LUBRICATIO NEngine OilAlways check and change the oil at the intervals outlined in thePeriodic Maintenance Chart beginning on page
62MAINTENANCE AND LUBRICATIO NEngine OilOil an d F ilter Change (2x4, 4X4)CAUTIONHot oil can cause serious burns. Do not allow hot oil to come intocon
563MAINTENANCE AND LUBRICATIO NEngine OilOil an d F ilter Change (2x4, 4X4)8. Reattach the oil line.9. Place shop towels beneath theoil filter (5). Us
64MAINTENANCE AND LUBRICATIO NEngine OilOil Pump Priming (2x4, 4X4)This priming procedure m ust beperformed whenever the oil hoseconnection between th
65MAINTENANCE AND LUBRICATIO NEngine OilOil Check (TM)1. Position the vehicle on a levelsurface.2. Start the engine and let it idle for20-30 seconds.3
66MAINTENANCE AND LUBRICATIO NEngine OilOil an d F ilter Change (TM)1. Position the vehicle on a level surface.2. Run the engine two to three minutes
4VEHICLE IDENTIFICATION NUMBERSRecord your vehicle’s identification numbers and key number in thespaces provided. Remove the spare key and store it in
67MAINTENANCE AND LUBRICATIO NEngine OilOil an d F ilter Change (TM)7. Place shop towels beneath the oilfilter (1). Using an oil filterwrench (2), tur
68MAINTENANCE AND LUBRICATIO NGearcasesGearcase Specification ChartGearcase Lubricant Capacity Fill PlugTorqueDrain PlugTorqueMain Gearcase(Transmissi
69MAINTENANCE AND LUBRICATIO NGearcasesTransmission (Main Gearcase)Always check and change the transmission oil at the intervals outlinedin the Period
70MAINTENANCE AND LUBRICATIO NGearcasesFront Gearcase (4X4)Always check and change the front gearcase oil at the intervalsoutlined in the Periodic Mai
1212TM2X44X471MAINTENANCE AND LUBRICATIO NGearcasesRear GearcaseAlways check and change the rear gearcase oil at the intervals outlinedin the Periodic
72MAINTENANCE AND LUBRICATIO NCooling System (2X4, 4X4)OperationThe engine coolant level is controlled or maintai ned by the recoverysystem. The recov
73MAINTENANCE AND LUBRICATIO NCooling System (2X4, 4X4)Radiator and Cooling FanAlways check and clean the screen and radiator fins at the intervalsout
174MAINTENANCE AND LUBRICATIO NCooling System (2X4, 4X4)Radiator Coolant LevelAlways check and change the coolant at the intervals outlined in thePeri
75MAINTENANCE AND LUBRICATIO NSpark PlugsCAUTIONUsing non-recommended spark plugs can result in serious enginedamage. Always use Polaris-recommended s
76MAINTENANCE AND LUBRICATIO NPolaris Variable Transmission (PVT) SystemWARNINGFailure to comply with the instructions in this warning can result inse
5SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin severe injury or death.A Polaris RANGER is not a toy
77MAINTENANCE AND LUBRICATIO NVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the vehicle is not thoroughly
178MAINTENANCE AND LUBRICATIO NFilter Systems (2X4, 4X4)Air FilterAlways change the air filter at the intervals outlined in the PeriodicMaintenance Ch
79MAINTENANCE AND LUBRICATIO NFilter Systems (2X4, 4X4)Breather Filter and Hoses1. Lift the cargo box and locate theair box.2. Follow the right-hand b
80MAINTENANCE AND LUBRICATIO NFilter Systems (TM)Air FilterAlways check and change the airfilter at the intervals outlined in thePeriodic Maintenance
81MAINTENANCE AND LUBRICATIO NCarburetor/Engine Idle RPM AdjustmentThe idle speed adjustment should be performed as outlined in thePeriodic Maintenanc
82MAINTENANCE AND LUBRICATIO NSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious in
83MAINTENANCE AND LUBRICATIO NSpark ArrestorUse the following procedure to periodically purge accumulated carbonfrom the exhaust pipe.1. Remove the ar
1284MAINTENANCE AND LUBRICATIO NThrottle SystemWARNINGFailure to check or maintain proper operation of the throttlesystem can result in an accident an
85MAINTENANCE AND LUBRICATIO NThrottle SystemThrottle Freeplay Inspection1. Apply the parking brake (2) and shift the transmission to neutral.2. Start
186MAINTENANCE AND LUBRICATIO NBrakesThe front and rear brakes are hydraulic disc type brakes. Press down onthe brake pedal to engage the brakes. See
6SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your RANGER. Your safety is involved when thesewords
87MAINTENANCE AND LUBRICATIO NBrakesBrake Inspection1. Check the brake system for fluidleaks.2. Check the brake pedal for excessivetravel or a spongy
88MAINTENANCE AND LUBRICATIO NSteering Wheel InspectionCheck the steering wheel for specified freeplay and smooth operationat the intervals outlined i
89MAINTENANCE AND LUBRICATIO NSeat BeltsInspect all three seat belts for proper operation before each use of thevehicle.1. Push the latch plate into t
90MAINTENANCE AND LUBRICATIO NTiresWARNINGOperating your vehicle with worn tires will increase the possibilityof skidding, loss of control and an acci
91MAINTENANCE AND LUBRICATIO NTiresWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in serious
192MAINTENANCE AND LUBRICATIO NLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causin
193MAINTENANCE AND LUBRICATIO NLightsHeadlight Beam Adjustment1. Place the vehicle on a level surface with the headlightapproximately 25 ft. (7.6 m) f
94MAINTENANCE AND LUBRICATIO NLightsIndicator L amp Replacement1. Lift the hood.2. Reach in behind the consolepanel and lift the release (1) tounplug
95MAINTENANCE AND LUBRICATIO NCleaning Your RANGERKeeping your vehicle clean will not only improve its appearance but itcan also extend the life of va
96MAINTENANCE AND LUBRICATIO NStorageIf your vehicle is to be placed in extended or off season storage, thefollowing steps should be taken to preserve
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