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WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
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WELCOME ThankyouforpurchasingaPolaris vehicle, andwelcometoour world-widefamilyofPolaris owners. Weproudlyproduceanexciting lineofutilityandrecreational products. S Snowmobiles S All-terrainvehicles (ATVs) S RANGERutilityvehicles S Victory motorcycles WebelievePolaris sets astandardofexcellenceforall utilityand recreational vehicles manufacturedintheworldtoday. Manyyears of experiencehavegoneintotheengineering, design, anddevelopment of yourPolaris vehicle, makingit thefinest machinewe’veever pr
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Copyright2005PolarisSalesInc.Allinformationcontainedwithinthispublicationis basedonthelatestproductinformationatthetimeofpublication. Duetoconstant improvementsin thedesign and quality ofproductioncomponents,someminor discrepanciesmay resultbetween theactualvehicleand theinformation presented in this publication. Depictionsand/orproceduresinthispublicationareintendedforreference useonly.No liability can beaccepted foromissionsorinaccuracies. Any reprinting or reuseofthedepictionsand/orprocedures
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TABLEOFCONTENTS VEHICLE IDENTIFICATION NUMBERS........ 4 SAFETY ................................... 5 FEATURES AND CONTROLS ............... 23 OPERATION .............................. 32 EMISSION CONTROL SYSTEMS ............ 51 MAINTENANCE AND LUBRICATION ......... 53 POLARIS PRODUCTS..................... 101 SPECIFICATIONS ........................ 102 TROUBLESHOOTING ..................... 108 WARRANTY.............................. 111 MAINTENANCE LOG...................... 120 INDEX ............
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VEHICLEIDENTIFICATIONNUMBERS Recordyourvehicle’s identificationnumbers andkeynumberinthe spaces provided. Removethesparekey and storeit in asafeplace. YourkeycanbeduplicatedonlybymatingaPolaris keyblankwith oneofyourexistingkeys, soifbothkeys arelost, theignitionswitch must bereplaced. 2 31XX 3 1 VehicleModelNumber: (behindleft front wheel) FrameVIN (1): (under hood) EngineSerialNumber (2): (right front sideof enginecrankcase) Key Number (3): 4
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SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner’s manual and all warnings befor
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SAFETY Operator Safety Thefollowingsignal words andsymbols appearthroughout this manual and on your RANGER. Yoursafetyis involvedwhenthese words andsymbols areused. Becomefamiliarwiththeirmeanings beforereadingthemanual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death. CAUTION The safety alert caution indicates a potential hazard th
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SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Readthis manual andall labels carefully. Followtheoperatingpro- cedures described. S Neverallowanyonewithout avaliddriver’s licensetooperatethis vehicle. S Minimum agerecommendationforpassengers is fiveyears old. Pas- sengers underfiveyears ofagerequirespecial restraints whichare not availablewiththis vehicle.
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SAFETY Operator Safety S Always followproperprocedures forturning as described in this manual. Practiceturningat slowspeeds beforeattemptingtoturnat fasterspeeds. Neverturnat excessivespeeds. S Always havethis vehiclechecked by an authorized Polaris dealerif it has been involved in an accident. S Neveroperatethis vehicleonhills toosteepforthevehicleorfor yourabilities. Practiceonsmallerhills beforeattemptinglargerhills. S Always followproperprocedures forclimbinghills as describedin this manual.
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SAFETY Operator Safety S Nevermodifythis vehiclethroughimproperinstallationoruseof accessories. S Neverexceed thestated load capacity forthis vehicle. Cargo should beproperly distributed and securely attached. Reducespeed and followtheinstructions inthis manual forhaulingcargoorpullinga trailer. Allowagreaterdistanceforbraking. S Always weartheseat belts whenoperatingthis vehicle. Seat belts reducetheseverityofinjuryincaseofasuddenstoporcollision. S Always keeparms andlegs insidethecabframewhile
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SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is design
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. Ifyouloseallforward speed: Apply the brakes. Lock the parking brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake. In the event of an accident, have a qualified service dealer check the complete vehic
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops. WARNING POTENTIAL
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways. WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judg
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZAR
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accide
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SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. CAUTION Always keep combustible materials away from the exhaust system. Exposure to the hot component
