Polaris 2014 RANGER 400, Owner'S Manual

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RANGER 400 ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...y 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 produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but i...

Page 4: ...y result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle a...

Page 5: ...S Introduction 4 Safety 8 Features and Controls 21 Operation 28 Winch Guide 42 Emission Control Systems 51 Maintenance 52 POLARIS Products 85 Specifications 86 Troubleshooting 88 Warranty 92 Maintenance Log 98 Index 101 ...

Page 6: ...tential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation tha...

Page 7: ...afety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor ...

Page 8: ...ne of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ________________________________________________________________________ Frame VIN _________________________________________________________________________________ Engine Serial Number ________________________________________________________________________ label on side of engine Key Number __...

Page 9: ... condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmen...

Page 10: ... a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will...

Page 11: ... and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at l...

Page 12: ...e The part number is printed on the label Max Payload Warning WARNING 7180136 Proper Use Warning Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off h...

Page 13: ...ailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steeri...

Page 14: ...utch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7175488 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle A...

Page 15: ... over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce roll...

Page 16: ...is manual for traveling downhill and for braking on hills See page 35 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles s...

Page 17: ...age 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory or modify the vehicle for the purpo...

Page 18: ...how to operate the vehicle properly in different situations and on different types of terrain All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs ...

Page 19: ...e Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications...

Page 20: ...haust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat...

Page 21: ...nfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s ma...

Page 22: ...icle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over y...

Page 23: ... operator and passengers at all times The vehicle illustrated below is shown without cab nets only to allow component identification Always use the cab nets or doors ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Headlights Front Bumper Brush Guard Radiator Cab Net Tailgate Latch Releases Receiver Hitch CV Boot Rear Caliper Muffler Spark Arrester Tailgate ...

Page 24: ... may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Indicator Lights Indicator Lights Cup Holder Storage Compartment 12V Auxiliary Outlet Storage Tray Gear Selector Shifter High Gear Low Gear Neutral Gear Reverse Gear High Temperature Park Gear ...

Page 25: ... problems NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads Brake Pedal Depress the ...

Page 26: ...n two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed See page 40 for Differential Lock operating instructions OFF The engine is off Electrical circuits are off except Acc 12V LIGHTS ON Lights are on Electrical circuits a...

Page 27: ...um pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Roll Over Protection System ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant ...

Page 28: ... sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the ...

Page 29: ...ets and latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is ...

Page 30: ...oline Heed the gasoline warnings on page 18 2 Check the oil level See page 56 Add the recommended oil as needed to maintain the oil level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls a...

Page 31: ...n 72 Tires Inspect condition and pressure 12 73 Wheels fasteners Inspect ensure fastener tightness 73 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 25 56 Coolant level Ensure proper level 63 Coolant hoses Inspect for leaks Throttle Ensure proper operation 70 Indicator lights switches Ensure operation 22 24 Air filter pre filter Inspect clean 67 Air box sedim...

Page 32: ...start within five seconds release the ignition switch and wait five seconds Repeat steps 7 and 8 until the engine starts 9 If a warm engine has cooled to a point where it does not readily start intermittent use of the choke half way out may be necessary If the engine is over choked when warm depress the throttle pedal fully while cranking to aid in starting Release the throttle pedal immediately a...

Page 33: ... 1 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 2 Sit in the driver s seat and fasten the seat belt 3 Start the engine and allow it to warm up 4 Always use the cab nets or doors while riding in this vehicle 5 Apply the service brakes and shift the transmission into gear 6 Check your surroundings and determine your path of travel 7 Keeping both hands on ...

Page 34: ... ride only in a passenger seat 7 Slow down Always travel at a speed appropriate for your skills your passenger s skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 8 Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 9 Always follow all operating guidelines as outline...

Page 35: ...ecautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and f...

Page 36: ...g weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels...

Page 37: ...could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill Driving Downhill Wh...

Page 38: ...rst opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could re...

Page 39: ...ed securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and...

Page 40: ...when towing See page 37 Towing a trailer increases braking distance 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 86 6 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle 7 Never tow a trailer on a grade steeper than...

Page 41: ...o the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 7 Lower the cargo box and push down securely to latch 8 Close the tailgate and secure both tailgate latches WARNING Operating the vehicle while the cargo bo...

Page 42: ...e in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Differential Unlocked Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD When the rear differential is unlocked the rear wheels can rotat...

Page 43: ...itch is turned off Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions i...

Page 44: ...le winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and mov...

Page 45: ...run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable bef...

Page 46: ...g strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 47: ...arts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kil...

Page 48: ...e moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 49 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the...

Page 49: ... is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook...

Page 50: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 51: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and poss...

Page 52: ...ation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purc...

Page 53: ...er by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at POLARIS specifications to achieve optimal performance Engine idle speed is the only adjustment POLARIS recomme...

Page 54: ...se must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collec...

Page 55: ... change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Ź E Air filter main element Weekly Inspect replace as needed Ź D Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test Ź E Engine breather filter if equipped 25 H Monthly Inspect replace if necessary Ź Engine oil change break in 25 H 1 M Perform a b...

Page 56: ...pect level change yearly Ź Middle Gearcase oil if equipped 100 H 6 M Inspect level change yearly Ź Rear gearcase oil if equipped 100 H 6 M Inspect level change yearly Ź Transmission oil 100 H 6 M Inspect level change yearly D E Fuel system 100 H 12 M Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years D Fuel filter 100 H 12 M Replace yearly Ź Radiator ...

Page 57: ...tems not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil See page 56 Brake Fluid DOT 4 Brake Fluid See page 71 Main Gearcase Oil Transmission AGL Gearcase Lubricant Transmission Fluid See page 59 Front Gearcase Oil Demand Drive Fluid See page 60 Front Prop Shaft Yoke U Joint Grease Locate fittings and grease 3 pumps ma...

Page 58: ...need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommendations for ambient temperature operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface ...

Page 59: ...plug and oil tank should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 9 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting Tip The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 10 Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns i...

Page 60: ...ned add about 1 3 4 quarts 1 6 l initially 19 Reinstall the dipstick 20 Prime the oil pump using the procedure below Then stop the engine and inspect for leaks 21 Check the oil level on the dipstick Add oil as necessary to bring the level to the upper mark on the dipstick 22 Dispose of used filter and oil properly Oil Pump Priming This priming procedure must be performed whenever the oil hose conn...

Page 61: ...he level check fill plug Check the oil level 3 Remove the rear fill plug and add the recommended oil as needed 4 Reinstall both fill plugs Torque to specification Oil Change The drain plug is located near the bottom of the gearcase 1 Remove the rear fill plug and the level check fill plug 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to drain completely 4 Clean and r...

Page 62: ... on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right ...

Page 63: ...lug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the ser...

Page 64: ...ommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 85 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the coo...

Page 65: ...e screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can caus...

Page 66: ...d 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 operation Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compartments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of c...

Page 67: ... completely Reinstall the drain plug 3 Place the transmission in PARK 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range 7 Test for belt slippage If the bel...

Page 68: ...cement is required if water is present 6 Thoroughly dry the air pre cleaner located under the hood 7 Turn the engine over several times using the electric start 8 Inspect the drained fuel for water or sediment 9 Dry the spark plug and reinstall it or install a new plug 10 Tighten the carburetor drain screw 11 Reconnect the fuel pump wires 12 Attempt to start the engine If necessary repeat the dryi...

Page 69: ... oil or water deposits If present drain them into a suitable container 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 Breather Filter and Hoses 1 Lift the cargo box and locate the air box 2 Follow the right hand breather line out the side of the air box and locate the fi...

Page 70: ...nt If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted 1 Apply the brakes 2 Place the transmission in PARK 3 Start the engine and allow it to warm up for approximately five minutes 4 Remove the seat Locate the idle adjust screw 5 Place the transmission in gear 6 Turn the screw in clockwise to raise RPM Turn the screw out counter clockwis...

Page 71: ...der the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 If carbon is expelled cover or plug the exhaust outlet...

Page 72: ...als outlined in the Periodic Maintenance Chart beginning on page 52 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm Throttle Freeplay Adjustment 1 Remove the lower ...

Page 73: ...mendations 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspec...

Page 74: ...e 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter clockwise to increas...

Page 75: ...f tires for this vehicle when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Aluminum Wheels Front and Rear 30 ft lbs 41 ...

Page 76: ...position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dea...

Page 77: ...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 Apply the brakes Start the engine Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below t...

Page 78: ...ON position 2 Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb Indicator Lamp Replacement 1 Lift the hood 2 Reach in behind the console panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indicator light assembly...

Page 79: ...ttery which requires little maintenance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep 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 ...

Page 80: ... battery and result in a shorter life It can also hinder vehicle performance Always install a fully charged battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the fra...

Page 81: ...S Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 85 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check th...

Page 82: ...ltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the volta...

Page 83: ... or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and lab...

Page 84: ... the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exteri...

Page 85: ...0 45 ml of engine oil 2 Reinstall the spark plug Torque to specification See page 61 3 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 4 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 5 Treat the fuel system with POLARIS Carbon Clean See page 82 If POLARIS fue...

Page 86: ...rvals outlined in the Periodic Maintenance Chart beginning on page 52 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Secure the fuel cap oil cap hood and cargo box Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transpor...

Page 87: ...3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 l 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2871460 Premium Starter Grease 2871...

Page 88: ...us 150 in 381 cm Towing Capacity 1250 lbs 567 kg Max Cargo Box Load 500 lbs 227 kg Engine 4 valve 4 stroke single cylinder with counter balance Lubrication System Dry Sump Cooling Liquid Engine Oil 2W 50 Displacement 455 cc Bore x Stroke mm 87 9 x 75 Pilot Jet 42 5 Main Jet 150 Needle Jet P 6 829 Jet Needle 4IB33 Air Screw 2 75 Alternator Output 250 W Compression Ratio 9 7 1 Starting System Electr...

Page 89: ... Brake Light 10 L E D 3 1W Indicator Light 1 0 W Altitude Shift Weight Drive Spring Driven Spring Meters Feet 0 1500 0 5000 10 MHF PN 5632281 Blue Red PN 7041157 Silver PN 7041499 1500 3700 5000 12000 10 RH PN 5630709 Blue Red PN 7041157 Silver PN 7041499 Altitude Meters Feet Ambient Temperature Below 40 F Below 5 C 40 F and above 5 C and above 0 1829 0 6000 155 150 1829 3048 6000 10 000 150 145 2...

Page 90: ...ssion to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle ro...

Page 91: ...gs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Overuse of choke Inspect clean and or replace spark plug Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect ...

Page 92: ... Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Possible Lean Fuel ...

Page 93: ...an and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your d...

Page 94: ... the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVE...

Page 95: ...ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY...

Page 96: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be ...

Page 97: ...utside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warra...

Page 98: ...rranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers comp...

Page 99: ... warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS ...

Page 100: ...98 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 101: ...99 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 102: ...100 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 103: ...Fasteners 66 D Differential Lock Switch 24 Differential Operation 40 Disengaging AWD 41 Drive Belt Wear 88 Drivetrain Break In 28 Driving Downhill 35 Driving in Reverse 33 Driving on a Sidehill 35 Driving on Slippery Surfaces 34 Driving Over Obstacles 33 Driving Procedure 31 Driving Through Water 36 Driving Uphill 35 Driving with a Passenger 32 Driving After Driving in Water 65 Dumping the Cargo B...

Page 104: ... Indicator Light Replacement 76 Indicator Lights 22 K Key Periodic Maintenance Chart 52 L Lamp Replacement Indicator Lights 76 Light Switch 24 Lights Brake Lights 76 Headlight Beam Adjustment 75 Headlight Lamp Replacement 76 Indicator Lamp Replacement 76 Indicator Lights 22 Lubrication Recommendations 55 M Main Gearcase 59 Maintenance Log 98 Maintenance Periodic 52 54 Modifications 15 O Obstacles ...

Page 105: ...el Inspection 72 Stopping the Engine 31 Storage 81 83 Storage Area 83 Storage Tips 82 83 Storage Battery 79 Storage Covers 83 S Storage Removal From 84 Switches AWD Switch 24 Differential Lock Switch 24 Ignition Switch 24 Light Switch 24 T Throttle Freeplay 70 Throttle Freeplay Adjustment 70 Throttle Freeplay Inspection 70 Throttle Pedal 23 Throttle System 70 Tire Pressure 12 Tires 73 74 Nut Torqu...

Page 106: ...ear your seat belt Vehicle rollover can cause severe injury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passengers read and understand all safety labels Operate slowly in reverse avoid sharp turns or sudden braking On paved surfaces pavement may seriously affect handling and control With non Polaris approve...