Owners Manual
Page 10
.... Operator Safety SAFETY WARNING Serious injury or death can result if you use it to make sure it's in safe operating condition. S Never allow anyone without a valid driver's license to changing terrain. S This vehicle is for the terrain, visibility and operating conditions, and your owner's manual. S Always inspect your vehicle each time you do not follow the inspection and maintenance procedures and schedules described...
.... Operator Safety SAFETY WARNING Serious injury or death can result if you use it to make sure it's in safe operating condition. S Never allow anyone without a valid driver's license to changing terrain. S This vehicle is for the terrain, visibility and operating conditions, and your owner's manual. S Always inspect your vehicle each time you do not follow the inspection and maintenance procedures and schedules described...
Owners Manual
Page 13
... vehicle, that increase speed or power. Failure of critical machine components may change the handling characteristics of certain accessories, including (but not limited to bodily injury. SAFETY Operator Safety WARNING Make sure your RANGER is designed. Modifications may also create a safety hazard and lead to ) mowers, blades, tires, sprayers, or large racks, may result from operation with their function and effect on your Polaris RANGER...
... vehicle, that increase speed or power. Failure of critical machine components may change the handling characteristics of certain accessories, including (but not limited to bodily injury. SAFETY Operator Safety WARNING Make sure your RANGER is designed. Modifications may also create a safety hazard and lead to ) mowers, blades, tires, sprayers, or large racks, may result from operation with their function and effect on your Polaris RANGER...
Owners Manual
Page 29
FEATURES AND CONTROLS Indicator Lights The indicator lights on page 47. High Gear 2. Reverse Gear 5. The connections are behind the console, under the hood. 1 Fuel Cap/Fuel Gauge (2) The fuel tank filler cap is located on the back that indicates the amount of the vehicle near the passenger seat. Brakes 2 Trailer Hitch Bracket 5 3 1 This vehicle is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on the...
FEATURES AND CONTROLS Indicator Lights The indicator lights on page 47. High Gear 2. Reverse Gear 5. The connections are behind the console, under the hood. 1 Fuel Cap/Fuel Gauge (2) The fuel tank filler cap is located on the back that indicates the amount of the vehicle near the passenger seat. Brakes 2 Trailer Hitch Bracket 5 3 1 This vehicle is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on the...
Owners Manual
Page 33
...: D: AWD (4X4 only) E: 2WD/Differential Lock F: Off See page 50 for differential operating instructions. Electrical circuits are off . WARNING Leaving the keys in the ON position to unauthorized use . The key can be in the ignition can be used. START Turn the key to the START position to the ON position when released. The engine is a three-position, key-operated switch. Always remove the ignition key when the vehicle is...
...: D: AWD (4X4 only) E: 2WD/Differential Lock F: Off See page 50 for differential operating instructions. Electrical circuits are off . WARNING Leaving the keys in the ON position to unauthorized use . The key can be in the ignition can be used. START Turn the key to the START position to the ON position when released. The engine is a three-position, key-operated switch. Always remove the ignition key when the vehicle is...
Owners Manual
Page 35
...-fitted engine parts. Drive slowly at 25 hours. 32 Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Pull only light loads. 7. OPERATION Vehicle Break-In Period The break-in period for your 4-cycle engine. 1. No single action on page 22. 2. Do not operate at sustained idle. 5. Fill the fuel tank with vehicle operation and handling. 4. Check the oil level...
...-fitted engine parts. Drive slowly at 25 hours. 32 Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Pull only light loads. 7. OPERATION Vehicle Break-In Period The break-in period for your 4-cycle engine. 1. No single action on page 22. 2. Do not operate at sustained idle. 5. Fill the fuel tank with vehicle operation and handling. 4. Check the oil level...
Owners Manual
Page 37
... the battery power will drop temporarily. Allow the engine to the START position while the engine is running. Starting a Cold Engine 1. NOTE: CAUTION 4 Do not operate the starter continuously for several minutes before attempting to allow it to cool and to start the TM model. Sit in half way (3). 8. After the engine starts, push the choke knob in the driver's seat and fasten the seat belt. Do not turn the ignition switch key...
... the battery power will drop temporarily. Allow the engine to the START position while the engine is running. Starting a Cold Engine 1. NOTE: CAUTION 4 Do not operate the starter continuously for several minutes before attempting to allow it to cool and to start the TM model. Sit in half way (3). 8. After the engine starts, push the choke knob in the driver's seat and fasten the seat belt. Do not turn the ignition switch key...
Owners Manual
Page 50
.... (386 kg) RANGER 2X4 4X4 RANGER Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 47 Hauling Cargo Towing Loads OPERATION WARNING Towing improperly can alter vehicle handling and may lose control of control or brake instability, which can result in serious injury or death. Towing a trailer increases braking distance. Do not attach a trailer to the trailer hitch bracket only. Attach a trailer to any other...
.... (386 kg) RANGER 2X4 4X4 RANGER Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 47 Hauling Cargo Towing Loads OPERATION WARNING Towing improperly can alter vehicle handling and may lose control of control or brake instability, which can result in serious injury or death. Towing a trailer increases braking distance. Do not attach a trailer to the trailer hitch bracket only. Attach a trailer to any other...
Owners Manual
Page 54
... the label. Remove the service panel (2) to the combustion chamber by gases are controlled by an authorized Polaris dealer. Engine idle speed is equipped with a closed crankcase system. The label on the RANGER 2X4 and 4X4 (3) is located on the recoil cover. Remove the seat and look through the exhaust system. Any other adjustments should be maintained at Polaris specifications to view the label...
... the label. Remove the service panel (2) to the combustion chamber by gases are controlled by an authorized Polaris dealer. Engine idle speed is equipped with a closed crankcase system. The label on the RANGER 2X4 and 4X4 (3) is located on the recoil cover. Remove the seat and look through the exhaust system. Any other adjustments should be maintained at Polaris specifications to view the label...
Owners Manual
Page 59
... for vehicles subjected to storage Inspect; Maintenance Interval Remarks " Engine breather E filter (if equipped) " Engine oil change " Oil tank vent hose J Valve clearance E " Perform these services. 56 adjust; adjust (break-in) " General lubrication Shift Linkage J Steering " Front suspension " Rear suspension Carburetor float bowl J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange Drive belt Cooling system (if applicable) " Engine oil change " Oil filter change Inspect; replace if necessary Perform a break-in oil change Inspect...
... for vehicles subjected to storage Inspect; Maintenance Interval Remarks " Engine breather E filter (if equipped) " Engine oil change " Oil tank vent hose J Valve clearance E " Perform these services. 56 adjust; adjust (break-in) " General lubrication Shift Linkage J Steering " Front suspension " Rear suspension Carburetor float bowl J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange Drive belt Cooling system (if applicable) " Engine oil change " Oil filter change Inspect; replace if necessary Perform a break-in oil change Inspect...
Owners Manual
Page 60
... perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; adjust when parts are replaced Inspect daily; Maintenance Interval Remarks J Fuel system E J Fuel filter E 100 H 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M 12 M - clean external surfaces Inspect for wear, routing, security; replace as needed " Radiator (if applicable) (if applicable) " Cooling hoses " Engine mounts Exhaust muffler/ pipe J Spark plug E E J Ignition Timing " Wiring J Clutches (drive and driven) bearings...
... perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; adjust when parts are replaced Inspect daily; Maintenance Interval Remarks J Fuel system E J Fuel filter E 100 H 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M 12 M - clean external surfaces Inspect for wear, routing, security; replace as needed " Radiator (if applicable) (if applicable) " Cooling hoses " Engine mounts Exhaust muffler/ pipe J Spark plug E E J Ignition Timing " Wiring J Clutches (drive and driven) bearings...
Owners Manual
Page 65
... of the oil tank. 2 3. Stop the engine. 2. Continue to rotate the fitting until warm. lbs. (19 Nm). 6. NOTE: The sealing surfaces on the oil drain plug. Run the engine two to 14 ft. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Maximum torque for the screen fitting is 25 ft. MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) CAUTION...
... of the oil tank. 2 3. Stop the engine. 2. Continue to rotate the fitting until warm. lbs. (19 Nm). 6. NOTE: The sealing surfaces on the oil drain plug. Run the engine two to 14 ft. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Maximum torque for the screen fitting is 25 ft. MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) CAUTION...
Owners Manual
Page 84
... the parking brake and place the gear shift lever in (clockwise) to lower RPM. 81 Warm up the engine by running the vehicle approximately five minutes. Remove the the seat and locate the idle adjust screw (1). 4. Turn the carburetor idle adjust screw in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER TM is 1000 +/- 100. TM 3. If the engine idle speed is...
... the parking brake and place the gear shift lever in (clockwise) to lower RPM. 81 Warm up the engine by running the vehicle approximately five minutes. Remove the the seat and locate the idle adjust screw (1). 4. Turn the carburetor idle adjust screw in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER TM is 1000 +/- 100. TM 3. If the engine idle speed is...
Owners Manual
Page 91
... shock mounting bolts. Remove the shock mounting bolts. 2. MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for proper torque at the first service or after 25 hours. Torque to increase or decrease spring tension. Position the vehicle on page 53. 1. The shocks are adjusted by an authorized Polaris dealer. Reposition the shocks to provide a stiffer suspension if necessary. Suspension Adjustment (2x4, 4X4) 1 The rear suspension of free play. 4. B A 88 Cylinder Head/Cylinder...
... shock mounting bolts. Remove the shock mounting bolts. 2. MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for proper torque at the first service or after 25 hours. Torque to increase or decrease spring tension. Position the vehicle on page 53. 1. The shocks are adjusted by an authorized Polaris dealer. Reposition the shocks to provide a stiffer suspension if necessary. Suspension Adjustment (2x4, 4X4) 1 The rear suspension of free play. 4. B A 88 Cylinder Head/Cylinder...
Owners Manual
Page 98
... pressure type car wash system is used , extreme care must be cleaned much like an automobile. Also run the vehicle to prevent water spots. NOTE: If warning labels are damaged, contact your vehicle is with a chamois to evaporate any water that may have entered the engine or exhaust system. 95 The best and safest way to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels...
... pressure type car wash system is used , extreme care must be cleaned much like an automobile. Also run the vehicle to prevent water spots. NOTE: If warning labels are damaged, contact your vehicle is with a chamois to evaporate any water that may have entered the engine or exhaust system. 95 The best and safest way to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels...
Owners Manual
Page 105
...Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug... (1.55 l) NA 2 valve 4 stroke twin cylinder 653 cc 2-80 x 65 50 140 NA NA 2.0 360 W 8.3 Electric 27 mm Nikki Magneto 26_ @ 3600 rpm BPR4EY 102 SPECIFICATIONS RANGER TM Gross Vehicle Weight Fuel Capacity Towing Capacity Max.
...Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug... (1.55 l) NA 2 valve 4 stroke twin cylinder 653 cc 2-80 x 65 50 140 NA NA 2.0 360 W 8.3 Electric 27 mm Nikki Magneto 26_ @ 3600 rpm BPR4EY 102 SPECIFICATIONS RANGER TM Gross Vehicle Weight Fuel Capacity Towing Capacity Max.
Owners Manual
Page 107
Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. SPECIFICATIONS RANGER 2x4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug 104 2500 lbs. (1135 kg) 8.5 gal. (32.2 l) 1400 lbs. (636 kg) 850 lbs. (386 kg...
Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. SPECIFICATIONS RANGER 2x4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug 104 2500 lbs. (1135 kg) 8.5 gal. (32.2 l) 1400 lbs. (636 kg) 850 lbs. (386 kg...
Owners Manual
Page 109
...) 132 in. (335.3 cm) 2 qts. (2.1 l) 2.25 qts. (2.4 l) 4 valve 4 stroke single cylinder with counter balance 499 cc 92 x 75 42.5 135 P-6 (829) 4MB32-3 2 1/2 250 W 10.2:1 Electric 34 mm CV Mikuni CDI 30_ @ 5000 rpm NGK BKR5E Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max.
...) 132 in. (335.3 cm) 2 qts. (2.1 l) 2.25 qts. (2.4 l) 4 valve 4 stroke single cylinder with counter balance 499 cc 92 x 75 42.5 135 P-6 (829) 4MB32-3 2 1/2 250 W 10.2:1 Electric 34 mm CV Mikuni CDI 30_ @ 5000 rpm NGK BKR5E Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max.
Owners Manual
Page 117
... and greater horsepower and the vehicle has a six (6) or four (4)-wheel drive and/or a round steering wheel." Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for this LSI engine must warrant the emission control system on your 2005 and later Large Spark Ignition Engine (herein "LSI engine"). Owner's Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in...
... and greater horsepower and the vehicle has a six (6) or four (4)-wheel drive and/or a round steering wheel." Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for this LSI engine must warrant the emission control system on your 2005 and later Large Spark Ignition Engine (herein "LSI engine"). Owner's Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in...
Owners Manual
Page 120
... E tube " Air filter, E main element " Engine breather E filter (if equipped) " Engine oil change E (break-in) J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange " Engine oil change E E E E E " Oil filter change at one month Replace with oil change Inspect routing, condition Inspect; adjust; adjust; lubricate; J Spark plug J Ignition Timing 117 Inspect; lubricate; California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval WARRANTY Remarks (whichever comes first) Hours Calendar Miles (Km) 25...
... E tube " Air filter, E main element " Engine breather E filter (if equipped) " Engine oil change E (break-in) J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange " Engine oil change E E E E E " Oil filter change at one month Replace with oil change Inspect routing, condition Inspect; adjust; adjust; lubricate; J Spark plug J Ignition Timing 117 Inspect; lubricate; California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval WARRANTY Remarks (whichever comes first) Hours Calendar Miles (Km) 25...
Owners Manual
Page 126
INDEX N Noise Emission Control System ...52 S Spark Arrestor ...82-83 Spark Plugs ...75 Specifications ...102-107 Starting a Cold Engine ...34 Starting a Warm Engine ...35 Starting the Engine ...34-35 Steering Wheel Inspection ...88 Stopping the Engine ...35 Storage ...96 Suspension Adjustment (2X4, 4X4) . 88 Switches ...30 O Oil and Filter Change (2x4, 4X4) . 62-63 Oil and Filter Change (TM) ...66-67 Oil Check (2x4, 4X4) ...61 Oil Check (TM) ...65 Oil Pump Priming (2x4, 4X4) ...64 Operator Safety ...5-17 P Parking Brake Adjustment ...87 Parking Brake Inspection ...87 Parking Brake Lever...
INDEX N Noise Emission Control System ...52 S Spark Arrestor ...82-83 Spark Plugs ...75 Specifications ...102-107 Starting a Cold Engine ...34 Starting a Warm Engine ...35 Starting the Engine ...34-35 Steering Wheel Inspection ...88 Stopping the Engine ...35 Storage ...96 Suspension Adjustment (2X4, 4X4) . 88 Switches ...30 O Oil and Filter Change (2x4, 4X4) . 62-63 Oil and Filter Change (TM) ...66-67 Oil Check (2x4, 4X4) ...61 Oil Check (TM) ...65 Oil Pump Priming (2x4, 4X4) ...64 Operator Safety ...5-17 P Parking Brake Adjustment ...87 Parking Brake Inspection ...87 Parking Brake Lever...