Polaris RANGER Diesel 2013, Owner'S Manual For Maintenance And Safety

Page 1: ...Owner s Manual for Maintenance and Safety Diesel RANGER ...

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: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...R S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924088 Rev 01 Printed in USA NEVER Operate ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle ...

Page 5: ... produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your POLARIS dealer knows your vehicle...

Page 6: ...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 liabil ity 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 ar...

Page 7: ... CONTENTS Introduction 4 Safety 6 Features and Controls 17 Operation 30 Emission Control Systems 49 Maintenance 50 Specifications 79 POLARIS Products 80 Troubleshooting 81 Warranty 84 Maintenance Log 90 Index 91 ...

Page 8: ...d all product labels Always use the cab nets while riding in this vehicle Always keep hands and feet inside the vehicle at all times The RANGER is an off road vehicle Familiarize yourself with all laws and regulations con cerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these wor...

Page 9: ..._______________________ Key Number _______________________________________________________________________________ European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicate...

Page 10: ...illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Clutch 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 imbalan...

Page 11: ...an 15 degrees 15 On public roads a collision can occur with a another vehicle With more than two passengers or passengers under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause sever...

Page 12: ...centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box 7177689 RANGER 4 x 4 6 x 6 Crew CA 4 x 4 CA 6 x 6 MAXIMUM CARGO BOX LOAD 1000 lbs 454 kg 1250 lbs 567 kg 1000 lbs 454 kg 600 lbs 272 kg 1250 lbs 567 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 REAR 10 69 FRONT 10 69 CENTER 10 69 REAR 10 69 FR...

Page 13: ...ol lowed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipm...

Page 14: ...vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Alway...

Page 15: ...e reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Alw...

Page 16: ... or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ...

Page 17: ...proved helmet that fits properly and eye protection goggles or face shield Operating With a Load on the 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 ...

Page 18: ...pect the entire machine for possible damage including but not limited to brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and your passengers skills Turning Improperly Turning im...

Page 19: ...ppery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Alw...

Page 20: ...e 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 your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the...

Page 21: ...ted below is shown without cab nets only to allow component identification Always use the cab nets Not all models come with all features Refer to the specifications section on page 79 Front Bumper Brush Guard Radiator ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Cab Net Tailgate Latch Release Receiver Hitch CV Boot Rear Caliper Muffler Spark Arrester Tailgate Storage Compartment Headligh...

Page 22: ... is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equipment can be used START After the wait to start indicator turns off turn the key to the START position to engage the electric starter The key returns to the ON position when released Ignition Switch Light Switch AWD Differential Switch Wait to Start Glow Plug Indicator Low Oil Pressure Indicator START O...

Page 23: ... to lock the differential and operate in rear wheel drive Press the bot tom of the switch to unlock the differential and allow the two rear drive wheels to operate independently See page 48 for differential lock operating instructions Wait to Start Glow Plug Indicator When the key is turned to the ON position the glow plug system activates and the wait to start indicator illuminates Do not crank t...

Page 24: ... for the RANGER High gear is intended for use on hard packed surfaces with light loads To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear 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 Tip Maintaining shift li...

Page 25: ...ert the operator Tip This feature will not operate properly if the park brake connector or switch under the hood mal functions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure pro...

Page 26: ...e Compartments A storage compartment is located under the driver s seat Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 45 46 Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Pu...

Page 27: ...ly replace worn or dam aged cab nets with new cab nets available from 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 properly secured in the slot at the base of the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Open...

Page 28: ...erious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted For lap st...

Page 29: ...h the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not oper ate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat bel...

Page 30: ...mediately clean off any fuel that splashes on the instrument cluster Rider Information Center The rider information center is located in the instrument cluster All segments will briefly light up and HOT may display at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to pro tect the electronic speedometer If...

Page 31: ...ning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immedi ately 8 Check Engine Warning Indicator This indicator is not active for this model 9 Mode Indicator Standard Modes Use the MODE button to toggle through the mode options Odometer Mode The odometer records the miles traveled by the vehicle Trip Meter Mode The trip meter records...

Page 32: ...ttery voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of...

Page 33: ...e button 4 Press and release the MODE button once to advance the setting by one hour Press and hold the MODE button to advance the hours quickly 5 If you scroll past the intended number press and hold the button until the hours cycle back to zero 6 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The ...

Page 34: ...peed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next 4 to 5 hours 4 During the break in period carefully observe the engine oil pressure and engine temper ature 5 Check the engine oil and coolant levels frequently during the break in period Perform regular checks on areas outlined on the daily pre ride inspection checklist See page 31 6 C...

Page 35: ...ressure 69 Wheels fasteners Inspect ensure fastener tightness 69 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 35 54 Coolant level Ensure proper level 60 Coolant hoses Inspect for leaks Throttle Ensure proper operation 66 Indicator lights switches Ensure operation 18 Air filter pre filter Inspect clean 64 Air box sediment tube Drain deposits whenever visible...

Page 36: ...or Ultra Low Sulfur fuel should be used Bio Diesel fuels see pages 33 34 NEVER mix kerosene used engine oil or residual fuels with diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tank and fuel handling equipment clean at all times Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additiv...

Page 37: ...uppliers Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of aluminum and zinc FIE components 2 Free water in FAME may result in plugging of fuel filters and increased bacterial growth 3 High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization 4 FAME may have ad...

Page 38: ...ng the specifications outlined above are not considered to be defects in mate rial or factory workmanship and are not covered under warranty The same applies to dam ages or other concerns induced by not complying with the recommended operating conditions of YANMAR engines with bio diesel fuel Handling Fuel WARNING Diesel fuel is flammable and explosive under certain conditions NEVER refuel with th...

Page 39: ...is vehicle See page 33 Bio diesel blended fuel has unique qualities that should be considered before using it in this vehicle Cold weather conditions can lead to plugged fuel system components and hard starting Bio diesel blended fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components Use of bio diesel blended fuel may res...

Page 40: ...n the engine for at least 30 minutes NOTICE Bio diesel blended fuel does not have long term stability and should not be stored for more than three months Operating Conditions NOTICE Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphe...

Page 41: ... maxi mum of five seconds Release the key when the engine starts 7 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 6 and 7 until the engine starts 8 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow th...

Page 42: ...3 Sit in the driver s seat and fasten the seat belt 4 Always use the cab nets while riding in this vehicle 5 Start the engine and allow it to warm up 6 Apply the service brakes and shift the transmission into gear 7 Check your surroundings and deter mine your path of travel 8 Release the park brake 9 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with y...

Page 43: ... secure their seat belt 5 Make sure all cab nets are properly secured 6 Do not carry more than two passengers in the 4X4 vehicle 7 Allow a passenger to ride only in a passenger seat 8 Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 9 Vehicle h...

Page 44: ... 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 overturn 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 15 maximum Driving Downhill When d...

Page 45: ...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 46: ...nches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visi ble Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before back ing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping...

Page 47: ...en 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 obsta cles 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 result in loss of control and lead to serio...

Page 48: ...ce of flame or sparks including any appliance with pilot lights 3 Turn the engine off 4 Engage the park brake 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in gear 3 Engage the park brake 4 Turn the engine off 5 Block the rear wheels ...

Page 49: ...oads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitc...

Page 50: ... 68 1 kg tongue weight on the towing bracket 2 Use low range Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 45 Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 79 4 Attach a trailer to the trailer hitch bracket only Do not attach a...

Page 51: ...box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 8 Stand clear and pull up on the cargo box release lever 9 Lift the front of the cargo box to dump the cargo 10 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo b...

Page 52: ...bs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m 2 Stop completely Shi...

Page 53: ...ne at www gpoaccess gov ecfr Exhaust Emission Control System Exhaust emissions are controlled by engine design A fuel injection system controls fuel delivery The engine and fuel injection components are set at the factory for optimal perfor mance and are not adjustable Your engine is designed to operate on low sulfur or ultra low sulfur diesel fuel only Use of any other fuel may result in your eng...

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 con taminants colle...

Page 55: ...years Radiator Daily Clean dust dirt from external surfaces daily Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace every 150 hours or more often D Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test Front Gearcase oil if equipped 25 H 1 M Perform a break in oil level check Mid...

Page 56: ...ge yearly Middle Gearcase oil if equipped 100 H 6 M Inspect level change yearly Rear gearcase oil if equipped 100 H 6 M Inspect level change yearly 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 throttle body replace lines every 2 years Radiator in applicable 100 H 12 M Inspect clean external surfaces Cooli...

Page 57: ... not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil See page 54 Brake Fluid DOT 4 Maintain level between fill lines See page 67 Main Gearcase Oil Transmission AGL PLUS Transmission Fluid See page 56 Front Gearcase Oil Demand Drive PLUS Fluid See page 57 Front Prop Shaft Yoke POLARIS Premium U Joint Lube Locate fittings and grease 3 pumps ma...

Page 58: ...E CI 4 for this vehicle Always use the the correct viscosity grade based on the ambient temperature expected during opera tion See the chart below Oil Viscosity Ambient Air Temperature Chart Oil Check The oil dipstick is located on the engine under the passenger seat 1 Position the vehicle on a level surface 2 Stop the engine 3 Remove the seat 4 Remove the dipstick Wipe it dry with a clean cloth 5...

Page 59: ...er Using an oil filter wrench turn the filter counter clockwise to remove it 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1...

Page 60: ... the right side of the transmission Access the drain plug from the rear right hand side of the vehicle 1 Remove the fill plug 2 Place a funnel into the skid plate hole and under the trans mission drain plug Place a drain pan under the vehicle at the location of the funnel 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque...

Page 61: ...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 hand...

Page 62: ...he gearcase Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed Do not overfill 4 Reinstall the fill plug Torque to specification Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain com pletely 4 Clean and reinstall the drain plug w...

Page 63: ...stem when adding coolant Mixing types can result in damage to the cooling system POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water Always follow the manufacturer s mixing recommendations for the free...

Page 64: ...d often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Coolant Level 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolan...

Page 65: ...ined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when repla...

Page 66: ...ge 7 Test for belt slippage If the belt slips repeat the process 8 Take the vehicle to your dealer for service as soon as possible Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow t...

Page 67: ...r drain to catch fluids water and fuel 3 Slightly loosen the bleed screw to relieve fuel pressure in the filter Do not tighten the screw at this time 4 Reach under the fuel filter and slightly loosen the drain valve until the fluids drain from the drain hole Do not completely unscrew the drain valve 5 When fluids stop draining from the valve tighten the valve firmly by hand only 6 Reconnect the ba...

Page 68: ...ion Use care to avoid damaging the fil ter element 4 Remove debris from the filter using low pressure compressed air Lightly blow from the inside out NOTICE Operating a diesel engine with a soiled or damaged air filter can result in engine damage Do not attempt to wash the filter Always replace a soiled or damaged filter with a new filter 5 Clean any oil or water deposits from the air box 6 Apply ...

Page 69: ...ocedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bot tom of the muffler 2 Place the transmission in neutral Engage the park brake Start the engine 3 Purge accumulated carbon from the system by momen tarily revving the engine several times 4 If carbon is expelled partially cover the exhaust outlet and rap on the pipe around t...

Page 70: ...iodic Maintenance Chart beginning on page 50 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Apply the brakes Engage the park brake Shift the transmission to neutral 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 Idle RPM Idle RPM is preset b...

Page 71: ...oir in the driver s side wheel well 3 The level should be between the upper MAX and lower MIN level lines 4 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or...

Page 72: ...needed Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals out lined in the Periodic Maintenance Chart beginning on page 50 1 Position the vehicle on level ground 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...

Page 73: ...ize and type 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 main tenance 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 Nm PLUS 1 4...

Page 74: ...rvice axle nuts that have a cotter pin installed See your POLARIS dealer 5 Attach the wheel nuts and washers and finger tighten 6 Carefully lower the vehicle to the ground 7 Torque the wheel nuts to specification See page 69 Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burn...

Page 75: ... the headlight approximately 25 ft 7 6 m from a wall 2 Place the transmission in gear Engage the park brake 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn on the headlights 5 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed...

Page 76: ...t Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Tip The 120 ohm resistor if equipped is used by your POLARIS dealer for power steering diagnos tics ...

Page 77: ...f with clean shop tow els Coat the terminals with dielectric grease or petroleum jelly Battery Removal 1 Remove the front seat 2 Disconnect the black battery cable first 3 Disconnect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a sho...

Page 78: ...aling strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 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 voltme...

Page 79: ...h can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water ma...

Page 80: ... air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrom...

Page 81: ...enance Chart beginning on page 50 Battery Maintenance See page 74 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 50 Front gearcase fluid Rear gearcase fluid Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fi...

Page 82: ...Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 50 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Engage the park brake 3 Stop the engine 4 Place the transmission in gear 5 Secure the fuel cap oil cap and seat 6 Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rop...

Page 83: ...R 3 Cylinder Inline Diesel Displacement 904 cc Bore x Stroke 72mm x 74mm Alternator Output 12V DC 55A Compression Ratio 23 5 1 Starting System Electric Fuel System Indirect Injection Front Suspension Dual A arm w 9 6 in 24 4 cm of travel Rear Suspension Independent w 9 in 23 cm of travel Lubrication System Pressurized Wet Sump Driving System Type PVT 4 wheel independent shaft lockable differential...

Page 84: ...rive Fluid 8 oz 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 ...

Page 85: ...ully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn 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 over turn Belt slippage from w...

Page 86: ...Loose electronic control box connections Inspect clean reinstall connectors Possible Cause Solution Out of fuel Refuel Clogged fuel filter water separator Replace Clogged air filter Replace Water is present in fuel Drain the fuel system and refuel replace fuel filter water separator Old or non recommended fuel Replace with fresh recommended fuel Water or fuel in crankcase Immediately see your POLA...

Page 87: ... line Inspect and replace Other mechanical failure See your dealer Possible Cause Solution Poor fuel quality or incorrect fuel Replace with recommended fuel Clogged fuel filter Replace Clogged air filter Replace Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Kinked or plugged fuel tank vent line Inspect and replace Other mechanical failure ...

Page 88: ... ing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This war ranty also does not c...

Page 89: ...IS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUEN TIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEG...

Page 90: ...elts hoses fuel injector nozzles lubricants and cleaning fluids This warranty does not cover the cost of shipping the product to or from your POLARIS dealership HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting war ranty service you must present your copy of the Warranty Registration form to the dealer THE COST O...

Page 91: ...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 Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obt...

Page 92: ...s for evaporative emissions As related to the evaporative emission control system The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO ...

Page 93: ... warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may ...

Page 94: ...90 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 95: ...l Care 76 Cleaning and Storage 75 77 Clothing 9 Cold Weather Operation 35 36 C Component Locations 17 Console 20 21 Coolant Level Overflow Bottle Coolant 60 Coolant Level Radiator 60 Coolant Adding or Changing 59 Cooling Fan 59 Cooling System 59 60 Corrosion Removal Chrome 76 D Differential Lock Switch 19 Differential Locking 48 Disengaging AWD 48 Drive Belt Wear 81 Driving Downhill 40 Driving in ...

Page 96: ... 19 Inspection Pre Ride 31 Instrument Cluster 26 29 Interference Electromagnetic 49 K Key Periodic Maintenance Chart 50 L Lamp Replacement Headlight 71 Light Switch 19 Lights 70 71 Load Capacity 46 Low Oil Pressure Indicator 19 Lubrication Recommendations 53 M Maintenance Log 90 Maintenance Periodic 50 52 Mode Button 20 Modifications to Vehicle 12 N Noise Emission Control System 49 O Obstacles 42 ...

Page 97: ...ction 68 Steering Wheel Adjustment 21 Stopping the Engine 37 Storage 75 77 Storage Area 77 Storage Compartments 22 S Storage Battery 74 Storage Covers 77 Storage Fluid Levels 77 Storage Oil and Filter 77 Storage Removal 78 Suspension Adjustment Rear 68 Switches 18 19 AWD Switch 19 Differential Lock Switch 19 Ignition 18 Light 19 T Throttle Freeplay 66 Throttle Freeplay Adjustment 66 Throttle Freep...