Owners Manual
Page 10
... handling and control. • Use proper RIDING TECHNIQUES to avoid vehicle overturns on hilly terrain, use can result in turns. • Wear eye protection. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. NEVER: • Operate on HILLS Warning steeper than two passengers...
... handling and control. • Use proper RIDING TECHNIQUES to avoid vehicle overturns on hilly terrain, use can result in turns. • Wear eye protection. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. NEVER: • Operate on HILLS Warning steeper than two passengers...
Owners Manual
Page 16
... that may change the handling characteristics of control may become aerodynamically unstable at speeds higher than those that increase its speed or power. Do not make any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of certain accessories, including (but not limited to bodily injury. Operator Safety WARNING SAFETY Make sure your RANGER is designed...
... that may change the handling characteristics of control may become aerodynamically unstable at speeds higher than those that increase its speed or power. Do not make any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of certain accessories, including (but not limited to bodily injury. Operator Safety WARNING SAFETY Make sure your RANGER is designed...
Owners Manual
Page 28
... to power an auxiliary light or other optional accessories or lights. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 44-47. Trailer towing equipment is equipped with this vehicle. Brakes Reverse Gear Low Gear (if equipped) High Temperature Neutral Gear High Gear Trailer Hitch Bracket This vehicle is not supplied with a receiver hitch bracket for a trailer hitch. The connections are behind the console, under the hood.
... to power an auxiliary light or other optional accessories or lights. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 44-47. Trailer towing equipment is equipped with this vehicle. Brakes Reverse Gear Low Gear (if equipped) High Temperature Neutral Gear High Gear Trailer Hitch Bracket This vehicle is not supplied with a receiver hitch bracket for a trailer hitch. The connections are behind the console, under the hood.
Owners Manual
Page 34
... for Differential Lock operating instructions. Switches Light Switch AWD/ Differential Switch Ignition Switch FEATURES AND CONTROLS High Beam Low Beam OFF AWD 2WD OFF Ignition Switch The ignition switch is off. OFF ON START The engine is a three-position, key-operated switch. Electrical equipment can lead to unauthorized use Light Switch The ignition switch key must be used. AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/turf mode). Move the rocker switch to the center...
... for Differential Lock operating instructions. Switches Light Switch AWD/ Differential Switch Ignition Switch FEATURES AND CONTROLS High Beam Low Beam OFF AWD 2WD OFF Ignition Switch The ignition switch is off. OFF ON START The engine is a three-position, key-operated switch. Electrical equipment can lead to unauthorized use Light Switch The ignition switch key must be used. AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/turf mode). Move the rocker switch to the center...
Owners Manual
Page 35
... treatment of Polaris Premium 4 Synthetic Oil for extended periods during the first three hours of gasoline. Perform the following procedures carefully. Fill the fuel tank with vehicle operation and handling. 4. Drive slowly at full throttle or high speeds for your part is the first twenty hours of operation, or the time it takes to use of a new engine will damage close-fitted engine parts.
... treatment of Polaris Premium 4 Synthetic Oil for extended periods during the first three hours of gasoline. Perform the following procedures carefully. Fill the fuel tank with vehicle operation and handling. 4. Drive slowly at full throttle or high speeds for your part is the first twenty hours of operation, or the time it takes to use of a new engine will damage close-fitted engine parts.
Owners Manual
Page 37
... injury or death. Engage the park brake. 3. NOTE: Do not use of five seconds. Turn the ignition key past the ON/RUN position to neutral. 4. Apply the brakes. Repeat steps 6 and 7 until it does not readily start within five seconds, release the ignition switch and wait five seconds. Release the throttle pedal immediately after the engine starts. If the engine does not start , intermittent use of the choke...
... injury or death. Engage the park brake. 3. NOTE: Do not use of five seconds. Turn the ignition key past the ON/RUN position to neutral. 4. Apply the brakes. Repeat steps 6 and 7 until it does not readily start within five seconds, release the ignition switch and wait five seconds. Release the throttle pedal immediately after the engine starts. If the engine does not start , intermittent use of the choke...
Owners Manual
Page 50
... trailer hitch bracket only. Towing a trailer increases braking distance. Model RANGER 4X4 RANGER 2X4 Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 km/h) 10 mph (16 km/h) Belt Life To extend belt...
... trailer hitch bracket only. Towing a trailer increases braking distance. Model RANGER 4X4 RANGER 2X4 Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 km/h) 10 mph (16 km/h) Belt Life To extend belt...
Owners Manual
Page 53
OPERATION All Wheel Drive (AWD) (4X4 Models) The illuminated amber AWD AWD Switch switch indicates that the vehicle is turned off while the front gearcase is moving, it may remain in AWD. If the switch is turned off . Engage the AWD before switching to remain locked unnecessarily. If the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 50 Disengaging AWD Under certain conditions, it will automatically disengage. If the front...
OPERATION All Wheel Drive (AWD) (4X4 Models) The illuminated amber AWD AWD Switch switch indicates that the vehicle is turned off while the front gearcase is moving, it may remain in AWD. If the switch is turned off . Engage the AWD before switching to remain locked unnecessarily. If the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 50 Disengaging AWD Under certain conditions, it will automatically disengage. If the front...
Owners Manual
Page 54
Federal regulations can be performed by engine design, including factory-set fuel delivery and ignition. All exhaust gases exit through the gap in accordance with the USDA Forest Service Standard 5100-1C. Engine idle speed is operated on Public Lands in the U.S.A. Noise Emission Control System EMISSION CONTROL SYSTEMS Do not modify the engine, intake or exhaust components, as doing so may violate laws governing the registration and...
Federal regulations can be performed by engine design, including factory-set fuel delivery and ignition. All exhaust gases exit through the gap in accordance with the USDA Forest Service Standard 5100-1C. Engine idle speed is operated on Public Lands in the U.S.A. Noise Emission Control System EMISSION CONTROL SYSTEMS Do not modify the engine, intake or exhaust components, as doing so may violate laws governing the registration and...
Owners Manual
Page 57
... suspension X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level E X Air filter, pre-filter E X Air box sediment tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 54 apply dielectric grease if replacing Inspect; Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected...
... suspension X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level E X Air filter, pre-filter E X Air box sediment tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 54 apply dielectric grease if replacing Inspect; Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected...
Owners Manual
Page 59
... severe use. X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E E Q Ignition timing X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - replace worn parts Inspect; adjust when parts are replaced Inspect daily; replace as needed Inspect periodically; clean external surfaces Inspect for wear, routing, security; Q Have an authorized Polaris dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every...
... severe use. X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E E Q Ignition timing X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - replace worn parts Inspect; adjust when parts are replaced Inspect daily; replace as needed Inspect periodically; clean external surfaces Inspect for wear, routing, security; Q Have an authorized Polaris dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every...
Owners Manual
Page 80
Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/200. Remove the seat. Turn the screw out (counterclockwise) to neutral. 3. Shift the transmission to lower RPM. Locate the idle adjust screw. 5. Turn the screw in gear. 6. Carburetor MAINTENANCE The idle speed adjustment should be adjusted. 1. Place the transmission in (clockwise) to warm up for the RANGER 2X4 and 4X4 is 1200 +/- 200. If the engine idle speed is changed. Recommended engine idle RPM for...
Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/200. Remove the seat. Turn the screw out (counterclockwise) to neutral. 3. Shift the transmission to lower RPM. Locate the idle adjust screw. 5. Turn the screw in gear. 6. Carburetor MAINTENANCE The idle speed adjustment should be adjusted. 1. Place the transmission in (clockwise) to warm up for the RANGER 2X4 and 4X4 is 1200 +/- 200. If the engine idle speed is changed. Recommended engine idle RPM for...
Owners Manual
Page 91
... to the center of the headlight and make a mark on the seat while performing this step. 5. Place the vehicle on the wall in step 2. Apply the brakes. Start the engine. Turn on the headlights. 4. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Close the hood and repeat steps 4-6 until the lamp is properly adjusted. Adjustment Screw View of the hood assembly. 6. If the headlight needs adjustment...
... to the center of the headlight and make a mark on the seat while performing this step. 5. Place the vehicle on the wall in step 2. Apply the brakes. Start the engine. Turn on the headlights. 4. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Close the hood and repeat steps 4-6 until the lamp is properly adjusted. Adjustment Screw View of the hood assembly. 6. If the headlight needs adjustment...
Owners Manual
Page 105
Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load 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 Front Suspension Rear Suspension 2500 lbs. (1135 kg) 1105 lbs. (501 kg) 113 in. (282 cm) 60 in. (152.4 cm) 58 in. (147.3 cm) 75 in. (190.5 cm) 76 ...
Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load 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 Front Suspension Rear Suspension 2500 lbs. (1135 kg) 1105 lbs. (501 kg) 113 in. (282 cm) 60 in. (152.4 cm) 58 in. (147.3 cm) 75 in. (190.5 cm) 76 ...
Owners Manual
Page 107
... 499 cc 92 x 75 42.5 135 P-6 (829) 4MB32-3 2.5 250 W 10.2:1 Electric 34 mm CV Mikuni CDI 30° @5000 RPM NGK BKR5E MacPherson strut w/8.25 in. (21 cm) of travel Independent w/9 in. (23 cm) of travel 104 SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max.
... 499 cc 92 x 75 42.5 135 P-6 (829) 4MB32-3 2.5 250 W 10.2:1 Electric 34 mm CV Mikuni CDI 30° @5000 RPM NGK BKR5E MacPherson strut w/8.25 in. (21 cm) of travel Independent w/9 in. (23 cm) of travel 104 SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max.
Owners Manual
Page 118
... horsepower and the vehicle has a six (6) or four (4)-wheel drive and/or a round steering wheel." Owner's Warranty Responsibilities: • As the LSI engine owner, you should contact the Polaris Warranty Department at no abuse, neglect or improper maintenance of your LSI engine is defective, the part will repair your warranty rights and responsibilities, you are responsible for the performance of the required maintenance listed in a reasonable amount of time...
... horsepower and the vehicle has a six (6) or four (4)-wheel drive and/or a round steering wheel." Owner's Warranty Responsibilities: • As the LSI engine owner, you should contact the Polaris Warranty Department at no abuse, neglect or improper maintenance of your LSI engine is defective, the part will repair your warranty rights and responsibilities, you are responsible for the performance of the required maintenance listed in a reasonable amount of time...
Owners Manual
Page 122
clean Inspect; Change oil more often in service at tank cap, lines, fuel valve, filter, pump, carburetor; adjust; replace if necessary Inspect; Q Due to perform this work unless you are familiar with oil change X Oil filter Engine breather hose Choke (enricher) cable Spark plug Q Ignition timing Q Fuel system Remarks Miles (Km) Inspect; replace if necessary Inspect; Q Valve clearance Q Idle speed 100 H 12 M As required - 119 Replace with mechanical repair. adjust Adjust 20 H 100 H Daily Weekly Monthly 6M 100 H 100 H 50 H 100...
clean Inspect; Change oil more often in service at tank cap, lines, fuel valve, filter, pump, carburetor; adjust; replace if necessary Inspect; Q Due to perform this work unless you are familiar with oil change X Oil filter Engine breather hose Choke (enricher) cable Spark plug Q Ignition timing Q Fuel system Remarks Miles (Km) Inspect; replace if necessary Inspect; Q Valve clearance Q Idle speed 100 H 12 M As required - 119 Replace with mechanical repair. adjust Adjust 20 H 100 H Daily Weekly Monthly 6M 100 H 100 H 50 H 100...
Owners Manual
Page 126
... Headlight Beam ...88 Park Brake...82 Rear Spring ...83 Rear Suspension ...83 Throttle Freeplay...80 Age Restrictions ...8 Air Filter ...75 Air Filter Cleaning ...75 All Wheel Drive ...50 All Wheel Drive Lock Switch ...31 Arrestor, Spark, Warning ...78 Auxiliary Outlet ...25 AWD ...50 AWD/Differential Lock Switch ...31 Axle Nut Torque ...85 C Changing Oil Engine ...60 Front Gearcase ...65 Rear Gearcase ...66 Transmission/Main Gearcase . . 64 Chart, Gearcase Specifications ...63 Chart, Periodic Maintenance ...52-56 Checking Oil Engine ...59 Front Gearcase ...65 Rear Gearcase ...66 Transmission...
... Headlight Beam ...88 Park Brake...82 Rear Spring ...83 Rear Suspension ...83 Throttle Freeplay...80 Age Restrictions ...8 Air Filter ...75 Air Filter Cleaning ...75 All Wheel Drive ...50 All Wheel Drive Lock Switch ...31 Arrestor, Spark, Warning ...78 Auxiliary Outlet ...25 AWD ...50 AWD/Differential Lock Switch ...31 Axle Nut Torque ...85 C Changing Oil Engine ...60 Front Gearcase ...65 Rear Gearcase ...66 Transmission/Main Gearcase . . 64 Chart, Gearcase Specifications ...63 Chart, Periodic Maintenance ...52-56 Checking Oil Engine ...59 Front Gearcase ...65 Rear Gearcase ...66 Transmission...
Owners Manual
Page 127
... Storage ...99 Fluid, Battery ...93 Fluid, Brake ...81 Fogging the Engine ...100 Fouled Plugs ...68 Freeplay Adjustment, Throttle...80 Freeplay, Steering Wheel...83 Front Gearcase Lubrication...65 Oil Change ...65 Oil Check ...65 Fuel Cap...26 Filter...75 Gauge...26 Safety ...21 Stabilizer ...99 K Key, Periodic Maintenance Chart ...53 L Lamp Replacement, Headlight ...87 Lamp Replacement, Indicator Lights 89 Level, Coolant ...70-71 Life of Belt...47 Light Switch ...31 Lights ...87-89 Lights, Brake ...89 Lights, Indicator...25 Load Capacity ...45 Loads, Towing ...47...
... Storage ...99 Fluid, Battery ...93 Fluid, Brake ...81 Fogging the Engine ...100 Fouled Plugs ...68 Freeplay Adjustment, Throttle...80 Freeplay, Steering Wheel...83 Front Gearcase Lubrication...65 Oil Change ...65 Oil Check ...65 Fuel Cap...26 Filter...75 Gauge...26 Safety ...21 Stabilizer ...99 K Key, Periodic Maintenance Chart ...53 L Lamp Replacement, Headlight ...87 Lamp Replacement, Indicator Lights 89 Level, Coolant ...70-71 Life of Belt...47 Light Switch ...31 Lights ...87-89 Lights, Brake ...89 Lights, Indicator...25 Load Capacity ...45 Loads, Towing ...47...
Owners Manual
Page 128
... Shifting Gears ...29 Signal Words ...9 Spark Arrestor Warning ...78 Spark Arrestor Cleaning ...78 Spark Plug Condition ...68 Gap ...67 Removal ...68 Torque...67 Recommendations...67-68 Fouled ...68 Specifications ...102-105 Specifications, Gearcase ...63 Speed, Towing ...47 Spring, Rear, Adjustment ...83 Stabilizing the Fuel ...99 Starting the Engine ...34-35 Steering Wheel Inspection ...83 Stopping the Engine ...35 P Park Brake Adjustment ...82 Inspection ...82 Release ...30 Parking on an Incline ...43 Parking the Vehicle...48 Periodic Maintenance Chart...
... Shifting Gears ...29 Signal Words ...9 Spark Arrestor Warning ...78 Spark Arrestor Cleaning ...78 Spark Plug Condition ...68 Gap ...67 Removal ...68 Torque...67 Recommendations...67-68 Fouled ...68 Specifications ...102-105 Specifications, Gearcase ...63 Speed, Towing ...47 Spring, Rear, Adjustment ...83 Stabilizing the Fuel ...99 Starting the Engine ...34-35 Steering Wheel Inspection ...83 Stopping the Engine ...35 P Park Brake Adjustment ...82 Inspection ...82 Release ...30 Parking on an Incline ...43 Parking the Vehicle...48 Periodic Maintenance Chart...