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WARNING Read, understand, and follow all of the instructions and safety precautions 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.
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WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polar
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation. Depictions and/or procedures in this publication are inte
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TABLE OF CONTENTS Vehicle Identification Numbers. . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Features and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Emission Control Systems . . . . . . . . . . . . . . . 57 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 108 Polaris Products. .
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VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost. Key Number #### VIN Engine Serial Number Vehicle Model Number: ___________________________________________________ Frame VIN: ___
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SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
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SAFETY Safety Decals and Locations Cab Frame/Seat Belt Warning Clutch Cover Warning Clutch Cover Warning WARNING NO STEP • 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. Cab Frame/Seat Belt Warning WARNING • VEHICLE ROLLOVER could cause severe injury or death. This cab
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SAFETY Safety Decals and Locations Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. Shift Discretionary Warning Caution WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: • Operate on public roads. A collision can occur with a another vehicle. • Carry more than two passengers, or passengers under age five. • Use ALCOHOL or DRUGS before or while operating this vehicle. • Operate at speeds too fast for your skills o
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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
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SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for 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 pote
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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. • Read this manual and all labels carefully. Follow the operating proce- dures described. • Never allow anyone without a valid driver's license to operate this vehicle. • Minimum age recommendation for passengers is five years old. Pas- sengers under five years of age require special restraints which are not
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SAFETY Operator Safety • Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. • Always follow proper procedures for
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SAFETY Operator Safety • Never modify this vehicle through improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and fol- low the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. • Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.
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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
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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. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brakes gradually. When fully stopped, engage the park brake. In the event of an accident, have a qualified service dealer check the comp
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle. WARNING POTENTIAL HAZARD Operating
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provi
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SAFETY Operator Safety 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 HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water. 17
