RANGER 400

RANGER 400 - Polaris

Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be.

RANGER 400

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle. • 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.

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9923132r01

PMS 419
RANGER 400
Owner's Manual
for Maintenance and Safety

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.

The text is printed on 100% recycled with 40% post-consumer waste (PCW).

PMS 419

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER Operate:

At speeds too fast for your skills or the conditions.

After or while using Alcohol or Drugs.

On hills steeper than 15 degrees

15 .

On public roads. A collision can occur with another vehicle.

With more than ONE passenger, or with 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 severe injury or death. Wear a helmet and eye protection and keep hands and feet in vehicle at all times. Use the cab nets. Reduce speed and use extra caution when carrying passengers. Avoid sharp turns or turns while applying heavy throttle. Operate slowly in reverse - avoid sharp turns or sudden braking. Make sure passenger reads and understands all safety labels. Watch for branches or other hazards that could enter vehicle.

READ OWNER'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. 9923132 Rev 01 Printed in USA

*9923132

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® · Low Emission Vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility 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 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 best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period. We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!
1

POLARIS, THE WAY OUT and RANGER are registered trademarks of POLARIS Industries Inc.
Copyright 2010 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 discrepancies may 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 are in English. Other languages are provided as translations of the original instructions.
Printed in U.S.A.
2011 RANGER 400 Owner's Manual
P/N 9923132
2

TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 18 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emission Control Systems . . . . . . . . . . . . . . . . . . . . 49 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . 102 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Declaration of Conformity. . . . . . . . . . . . . . . . . . . 107 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
3

INTRODUCTION
The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning 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 words and symbols are used. Become familiar with their meanings before reading the manual.
The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury. CAUTION A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
4

INTRODUCTION
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 this owner's manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the vehicle. · 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 ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds. · Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels. · Always use the cab nets while riding in this vehicle. · Always keep hands and feet inside the vehicle at all times.
5

INTRODUCTION
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
Vehicle Model Number: ___________________________________________________ Frame VIN: ____________________________________________________________ Engine Serial Number: ___________________________________________________ (label on side of engine) Key Number ____________________________________________________________

Safety Labels and Locations

SAFETY

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If any label becomes 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.

Container/Passenger/Tire Pressure Warning

WARNING

· Passengers can be thrown off. This can cause serious injury or death.

· Never carry passengers in cargo box.

Maximum Box Load 500 lbs. (227 kg)

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa):

FRONT TIRE - INFLATE TO 10 psi (68.9 kPa)

REAR TIRE - INFLATE TO 12 psi (82.7 kPa)

MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES. 1000 LBS. (455 kg)

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be 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.

Read Owner's Manual for more detailed loading information.

7175941

SAFETY
Safety Labels and Locations

Age 16 Warning

Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.

Age 16 Warning

NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver's license.

Shift Caution

7175566

CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle.
APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

7176170

Discretionary Warning
Shift Caution

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 imbalance, and excessive engine RPM which can result in serious injury or death.
7175488

Clutch Cover Warning

Safety Labels and Locations

SAFETY

Discretionary Warning

WARNING

Improper vehicle use can result in Severe Injury or Death.

NEVER Operate:

· At speeds too fast for your skills or the conditions.

· After or while using Alcohol or Drugs.

· On hills steeper than 15 degrees

15°.

· On public roads, a collision can occur with a another vehicle.

· With more than ONE passenger, or a passenger 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 severe injury or death.

· Wear a helmet and eye protection and keep hands and feet in vehicle at all times.

· Reduce speed and use extra caution when carrying a passenger.

· Avoid sharp turns or turns while applying heavy throttle.

· Operate slowly in reverse - avoid sharp turns or sudden braking.

· Make sure passenger reads and understands all safety labels.

· Watch for branches or other hazards that could enter vehicle.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7176169

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 procedures described.
· Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
· Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
· No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.
· The driver and any passenger must wear helmet, eye protection and seat belt at all times.
· Always use the cab nets 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 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. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experience. · Never attempt jumps or other stunts.
10

Operator Safety

SAFETY

· Always inspect your vehicle each time you use it to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

· Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

· Never operate on excessively rough, slippery or loose terrain.

· Always follow proper procedures for turning. 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 climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

· Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. 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 such as rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

· Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

SAFETY
Operator Safety
· Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have 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. Always maintain proper tire pressure as specified on safety labels.
· 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 follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.
· Always place the transmission in PARK before getting out of the vehicle.
· Always stop the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 15 for fuel safety warnings.
· Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800342-3764.
12

Operator Safety

SAFETY

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY
Operator Safety
WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident 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 ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.
Operating Without Instruction
Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand 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.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop. Riders must wear seat belts at all times. Always make sure the seat belts are secured for both the operator and passenger before riding.
Cab Nets
Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times.
14

Operator Safety

SAFETY

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

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 or medications before or while operating this vehicle.

Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
· Always exercise extreme caution whenever handling gasoline.
· Always stop the engine when refueling.
· Always refuel outdoors or in a well ventilated area.
· Remove flammable material containers from box before filling.
· Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
· Do not overfill the tank. Do not fill the tank neck.
· If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
· Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust 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 overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

SAFETY
Operator Safety
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 passenger's skills.
Operating on Pavement
This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it's unlawful to operate this vehicle on public streets, roads and highways.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
Operating on Slippery 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.
16

Operator Safety

SAFETY

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 37.

Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill.

If all forward speed is lost:
· Apply the brakes.
· Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

If you begin rolling downhill:
· Never apply engine power.
· Apply the brakes gradually until the vehicle is fully stopped.
· Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

Improper Tire Maintenance
Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.
Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating on Frozen Bodies of Water
Severe injury or death can result if the vehicle 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 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 vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use.

Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

FEATURES AND CONTROLS
Component Locations
Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets..
ROPS Cab Frame

Cargo Box

Hip Bar

Console

Fuel Tank Cap Headlights

Cab Net 18

Radiator Front Bumper/Brush Guard

FEATURES AND CONTROLS
Component Locations
Tailgate Latch Releases
Tailgate

Receiver Hitch

Muffler (Spark Arrestor)
CV Boot/Rear Caliper

Trailer Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.
To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 42-45.

FEATURES AND CONTROLS
Console

Indicator Lights

Gear Selector (Shifter)

Storage Compartment

Storage Tray

12V Auxiliary Outlet

Cup Holder

Auxiliary Outlet
The 12-volt receptacles have spade connections on the back that 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

High Temperature

Reverse Gear

Low Gear

Park Gear

Neutral Gear

High Gear

Switches

FEATURES AND CONTROLS

Ignition Switch/Light Switch

The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

OFF LIGHTS ON LIGHTS OFF START

The engine is off. Electrical circuits are off, except Acc, 12V.
Lights are on. Electrical circuits are on. Electrical equipment can be used.
Lights are off. Electrical circuits are on. Electrical equipment can be used.
Turn the key to the START position to engage the electric starter. Turn the key to the LIGHTS ON position after starting the engine.

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/ Two Wheel Drive (2WD) and Off
(1WD/Turf Mode).

AWD/Differential Switch

Press the top of the switch to engage All Wheel Drive (AWD). See page 47 for AWD operating instructions.

Move the switch to the center

position to lock the differential

and operate in two wheel drive

Ignition Switch

Choke

(2WD). Press the bottom of the

Light Switch

Knob

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 48 for Differential Lock operating instructions.

FEATURES AND CONTROLS
Gear Selector

H: High Gear L: Low Gear

Gear Selector

N: Neutral

R: Reverse

P: Park

Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads.

Whenever the vehicle is left unattended, always place the transmission in PARK.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.

NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

FEATURES AND CONTROLS

Brake Pedal
Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.

Throttle Pedal
Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 79 for throttle pedal adjustment procedures.

Brake Pedal

Throttle Pedal

FEATURES AND CONTROLS
Seat Belts

This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating.

Latch Plate

The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.

Buckle

WARNING! Falling from a moving vehicle could result in serious 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.

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 Belts

FEATURES AND CONTROLS

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 buckle. A click indicates that it's securely latched.

2. Push 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 operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.

FEATURES AND CONTROLS
Cab Nets
Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and passenger at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets 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 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.
Opening a Net
1. To exit the vehicle, release the top front latch. 2. Rotate the net rearward and slide the lower net rod out of the mount
to remove it. 3. Allow the net to hang freely outside the vehicle while dismounting.
Top Latch

Rod Mount

Net Rod

FEATURES AND CONTROLS
Seat Removal
Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
Fuel Cap
The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum 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.
27

FEATURES AND CONTROLS
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.

ROPS Cab Frame

No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle rollover.

Storage Compartment

A storage compartment is located under the driver's seat.

Storage Compartment

OPERATION
WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual.
Break-In Period
The break-in period for your new POLARIS RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.
29

OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 15.
2. Check the oil level. See page 57. 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 and areas outlined
on the daily pre-ride inspection checklist. See page 31. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at 25
hours.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
30

Pre-Ride Inspection

OPERATION

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item

Remarks

Page

Brake system/pedal travel Ensure proper operation

Brake fluid

Ensure proper level

Park gear

Ensure vehicle does not roll when in

PARK. Ensure PARK light illuminates.

Front suspension

Inspect, lubricate if necessary

Rear suspension

Inspect, lubricate if necessary

Steering

Ensure free operation

Tires

Inspect condition and pressure

Wheels/fasteners

Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level

Ensure proper level

Coolant hoses

Inspect for leaks

Throttle

Ensure proper operation

Indicator lights/switches

Ensure operation

Air filter, pre-filter

Inspect, clean

Air box sediment tube

Drain deposits whenever visible

Headlamp

Check operation, apply POLARIS

dielectric grease when lamp is

replaced

Brake light/tail lamp

Check operation, apply POLARIS

dielectric grease when lamp is

replaced

Seat Belts

Check length of belt for damage,

check latches for proper operation

Cab Nets

Check for wear or damage, ensure

proper installation

OPERATION
Starting the Engine

1. Always start the engine outdoors or in a well-ventilated area.

2. Turn the fuel valve on.

3. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.

4. Apply the brakes. Place the transmission in PARK.

5. Do not use the choke if starting a warm engine. Excessive use of the choke can cause spark plugs to become wet fouled.
6. If the engine is cold, pull the choke knob out until it stops.

FULL ON HALF ON

7. Turn the ignition key to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts. Turn the key to the LIGHTS ON position before driving.

Choke Knob

OFF

8. Do not press the throttle pedal while starting the engine. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Repeat steps 7 and 8 until the engine starts.

Starting the Engine

OPERATION

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 after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.
10. After the engine starts, push the choke knob in half way.
11. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.
12. Push the choke knob in.
NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
WARNING! A rolling vehicle can cause serious injury. Always place the transmission in PARK when stopping the engine.

Braking

1. Release the throttle pedal completely.
2. Press on the brake pedal evenly and firmly.
3. Practice starting and stopping (using the brakes) until you're familiar with the controls.
Tip: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.

OPERATION
Driving Procedure
1. Wear a helmet and eye protection. 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 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 the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving. 8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces. 9. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle. Never carry more than one passenger in this vehicle. Never allow a passenger to ride in the cargo box.
34

Driving with a Passenger

OPERATION

1. Perform the pre-ride inspection. See page 31.

2. Make sure any passenger is at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

3. Make sure your passenger is wearing an approved helmet and eye protection.

4. Make sure your passenger secures the seat belt.

5. Make sure all cab nets are properly secured.

6. Never carry more than one passenger in this vehicle. Never allow a passenger to ride in the cargo box. Allow a passenger to 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 outlined on safety labels and in this manual.

OPERATION
Driving On Slippery Surfaces
WARNING
Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.
Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing 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 are spinning. Always allow the wheels to stop spinning before engaging AWD.
5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

Sideways skid

Turn in direction of
skid

Driving Uphill

OPERATION

Whenever traveling uphill, follow these pre-
cautions:

1. Always travel straight uphill.

2. Avoid steep hills (15° maximum).

3. Keep both feet on the floor.

4. Always check the terrain carefully before ascending any hill.

15° maximum

5. Never climb hills with excessively slippery or loose surfaces.

6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

OPERATION
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 driving downhill, follow these precautions:
1. Avoid steep hills (15° maximum).
2. Drive straight downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible.
3. Slow down.
4. Apply the brakes slightly to aid in slowing.

15° maximum

Driving Through Water

OPERATION

Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards.

NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 72, and take the vehicle to your dealer at the first 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 fastflowing water.

Floorboard

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 serious injury or death. Never cross deep or fast-flowing water with your RANGER.
5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 50. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped) and all grease fittings.

OPERATION
Driving Over Obstacles
Follow these precautions 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 haz-
ards 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.
40

Driving in Reverse

OPERATION

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 backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly.
41

OPERATION
Hauling Cargo
WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always operate the vehicle with extreme care when hauling or towing loads. 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 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 maneuverability may be adversely affected, causing the vehicle to overturn. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.
42

Hauling Cargo

OPERATION

The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle. Never exceed the following capacities.

Model
RANGER 400

Maximum Capacities (Level Ground)
1000 lbs. (454 kg)

Cargo Box
500 lbs. (227 kg)

WARNING! Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. A passenger must always ride in the cab with seat belt fastened securely.

OPERATION
Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes.

3. Place the transmission in PARK.

4. Dismount the vehicle.

5. Ensure that the cargo is positioned evenly or toward the front of the cargo box.
6. Release the tailgate latches.

Release Lever

WARNING! If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the 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.

7. Stand clear and pull up on the cargo box release lever.

8. Lift the front of the cargo box to dump the cargo.

9. Lower the cargo box and push down securely to latch.

10. Close the tailgate and secure both tailgate latches.

WARNING! Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position.

Towing Loads

OPERATION

Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 42. 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 100.

4. 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.
5. Never tow a trailer on a grade steeper than 15°.

Model
RANGER 400

Total Towed Load Weight (Level Ground)
1250 lbs. (567 kg)

Total Towed Load Weight (15° grade)
850 lbs. (386 kg)

Total Hitch Vertical Weight
150 lbs. (68.1 kg)

Maximum Towing Speed
10 mph (16 kph)

Belt Life
To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

OPERATION
Parking the Vehicle
1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the
structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3. Place the transmission in PARK. 4. Turn the engine off. 5. Remove the ignition switch key to prevent unauthorized use.
Parking on an Incline
15° maximum
Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Block the rear wheels on the downhill side.
46

All Wheel Drive (AWD)

OPERATION

Press the top of the rocker switch to engage All Wheel Drive (AWD). The illuminated amber AWD switch indicates that the vehicle is in AWD.
When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.
Tip: The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch 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
Move the AWD switch to the center or bottom position to disengage AWD.
If the switch is turned off while the front gearcase is moving, it will not disengage 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.
2. Operate in reverse for at least 10 feet (3 m).
3. Stop completely.
4. Shift into low gear and drive forward.
5. If the front gearcase remains locked after following these instructions, return the vehicle to your dealer for service.

OPERATION
All Wheel Drive (AWD)
Locking the Differential
NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.
Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive. Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently. This mode of operation is well suited to turf driving or whenever aggressive traction is not required.
48

EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber 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 recommends that the operator perform. Any other adjustments should be performed by an authorized POLARIS dealer. The emissions label is located on the frame under the seat.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
49

MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 115.
Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten (10) miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
· Frequent immersion in mud, water or sand · 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 collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
50

MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) n Have an authorized POLARIS dealer perform these services.
WARNING! Improperly performing the procedures marked with a n could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
51

MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval
(whichever comes first)

Hours Calendar

Miles (Km)

n Steering

- Pre-Ride

X Front suspension

- Pre-Ride

X Rear suspension

- Pre-Ride

Tires

- Pre-Ride

X Brake fluid level

- Pre-Ride

X Brake pedal travel

Brake system

- Pre-Ride

Wheels/fasteners

- Pre-Ride

Frame fasteners

- Pre-Ride

X Engine oil level

- Pre-Ride

X Air filter, pre-filter

Daily

X Air box sediment

Daily

E tube

Coolant

Daily

(if applicable)

Headlamp/tail

Daily

lamp

X Air filter, E main element

Weekly

X Brake pad wear

10 H Monthly

Battery

20 H Monthly

X Front Gearcase Oil 25 H Monthly

(if equipped)

X Middle Gearcase 25 H Monthly

Oil (if equipped)

X Rear gearcase oil 25 H Monthly

(if equipped)

X Transmission oil 25 H Monthly

Remarks
Make adjustments as need ed. See Pre-Ride Checklist on page 31.
Inspect; clean often; replace as needed Drain deposits when visible Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing Inspect; replace as needed Inspect periodically Check terminals; clean; test Inspect level; change yearly Inspect level; change yearly Inspect level; change yearly Inspect level; change yearly

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. n Have an authorized POLARIS dealer perform these services.

MAINTENANCE
Periodic Maintenance Chart

Item
X Engine breather E filter (if equipped) X Engine oil change
(break-in) X General
lubrication Shift Linkage n Steering X Front Suspension X Rear Suspension Carburetor float bowl nE Throttle cable

Maintenance Interval
(whichever comes first)

Hours Calendar

Miles (Km)

25 H Monthly

25 H

1 M

50 H

3 M

50 H

6 M

50H

6 M

50 H

6 M

50 H

6 M

50 H

6 M

50 H

6 M

nE Choke cable

50 H

6 M

E Carburetor air

50 H

6 M

intake ducts/flange

Drive belt

50 H

6 M

Cooling system

50 H

6 M

(if applicable)

X Engine oil change 100 H 6 M

X Oil filter change 100 H 6 M

Remarks
Inspect; replace if necessary
Perform a break-in oil change at one month Lubricate all fittings, pivots, cables, etc. Inspect, lubricate, adjust Lubricate Lubricate Lubricate Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at one month Replace with oil change

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. n Have an authorized POLARIS dealer perform these services.

MAINTENANCE
Periodic Maintenance Chart

Item
nE Fuel system n Fuel filter

Maintenance Interval
(whichever comes first)

Hours Calendar

Miles (Km)

100 H 12 M

Remarks
Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years Replace yearly

X Radiator (in applicable)
X Cooling Hoses X Engine mounts
Exhaust muffler/ pipe X Spark plug E
nE Ignition timing X Wiring

100 H
100 H 100 H 100 H
100 H
100 H 100 H

12 M
12 M 12 M 12 M
12 M
12 M 12 M

n Clutches (drive and driven)
n Front wheel bearings
n Brake fluid
Spark arrestor
Idle speed
n Toe adjustment

100 H
100 H
200 H 300 H

n Auxiliary brake (if X equipped)
Headlight aim

12 M
12 M
24 M 36 M
-
-
-

Inspect; clean external

surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect

Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Inspect; clean; replace worn

parts

Inspect; replace as needed

Change every two years

Clean out

Adjust as needed

Inspect periodically; adjust when parts are replaced

Inspect daily; adjust as needed

Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. n Have an authorized POLARIS dealer perform these services.

MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item
Engine Oil
Brake Fluid Main Gearcase Oil (Transmission) Front Gearcase Oil Front Prop Shaft Yoke

Lube
PS-4 PLUS Performance Synthetic 2W-50
DOT 4
Premium AGL Synthetic Gearcase Lube
Demand Drive Plus Fluid
POLARIS Premium U-Joint Lube

Method
See page 57.
See page 80. See page 61.
See page 63. Locate fittings and grease (3 pumps maximum).

Prop Shaft U-Joint

MAINTENANCE
Engine Oil
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil.
WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 102 for the part numbers of POLARIS products.
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.
56

Engine Oil

MAINTENANCE

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. See page 56 for oil recommendations.

Oil Check
The oil tank is located under the seat.
1. Position the vehicle on a level surface. Place the transmission in PARK.
2. Start the engine and allow it to idle for 20-30 seconds. Stop the engine.
3. Remove the seat. See page 27.
4. Remove the dipstick. Wipe it dry with a clean cloth.
5. Reinstall the dipstick. Screw it in completely.
6. Remove the dipstick. Make sure that the oil level is in the safe range. Add oil if necessary. Do not overfill.
7. Reinstall the dipstick.

Safe Range

{

Add Oil

Safe

MAINTENANCE
Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.
3. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

Drain Plug

Screen Fitting

4. Clean the area around the oil tank drain plug.
5. Place a drain pan under the oil tank.

Sealing Washer

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

6. Remove the drain plug. Allow the oil to drain completely.

7. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and oil tank should be clean and free of burrs, nicks or scratches.

Alignment Mark

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 into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.

Tip: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34 Nm).

11. Reattach the oil line.

Engine Oil

MAINTENANCE

Oil and Filter Change

12. Place shop towels under the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it.

13. Using a clean dry cloth, clean the filter sealing surface on the engine.

14. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Make sure the gasket from the old filter is not still on the engine.

15. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

16. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase.

Tip: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

17. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

18. Remove the dipstick. Add two quarts (1.9 l) of recommended oil. If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.

19. Reinstall the dipstick.

20. Prime the oil pump using the procedure on page 60. 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.

MAINTENANCE
Engine Oil

Oil and Filter Change

Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

Tank

2" (5 cm)

1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.
2. Start the engine. Allow it to idle for 10-20 seconds.

Clamp
Pressure Relief Slit

3. Remove the vent line clamp. If the line is bled properly, you should hear a rush of air, indicating that the line is properly primed and ready for operation.

Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.

Gearcases
Gearcase Specification Chart

Gearcase

Lubricant

Capacity

Main Gearcase (Transmission)
Front Gearcase

Premium AGL Synthetic
Gearcase Lube
Demand Drive Plus Fluid

43.6 oz. (1290 ml)
9.3 oz. (275 ml)

MAINTENANCE

Fill Plug Torque
14 ft. lbs. (19.4 Nm)
8-10 ft. lbs. (11-13.6 Nm

Drain Plug Torque
14 ft. lbs. (19.4 Nm)
11 ft. lbs. (15 Nm)

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 102 for the part numbers of POLARIS products.

Oil Check

The fill plug is located at the rear of the vehicle.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

Fill Plug

5. Reinstall the fill plug. Torque to specification.

MAINTENANCE
Gearcases

Transmission (Main Gearcase)

Oil Change

The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. Refer to the Gearcase Specifications Chart on page 61 for recommended lubricants, capacities and torque specifications.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Drain the oil.

4. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings.

Drain Plug

5. After the oil has drained completely, install a new sealing washer.

6. Reinstall the drain plug. Torque to specification.

7. Add the recommended oil as needed. Do not overfill.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Dispose of used oil properly.

Gearcases

MAINTENANCE

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 61 for recommended lubricants, capacities and torque specifications. See page 102 for the part numbers of POLARIS products.

Oil Check

The front gearcase fill plug is located 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

Fill Plug

1. Support the vehicle securely with a jackstand.

2. Remove the front tire on the driver's side.

Drain Plug

3. Remove the fill plug.

4. Place a drain pan under the drain plug on the bottom right-hand side.

5. Remove the drain plug. Drain the oil.

6. Clean the drain plug. Reinstall the drain plug. Torque to specification.

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 100 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.
NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs.

Spark Plug Gap/Torque

Model RANGER 400

Electrode Gap .036" (.9 mm)

New Plug Torque
9-11 ft. lbs. (12-15 Nm)

Used Plug Torque
9-11 ft. lbs. (12-15 Nm)

Spark Plug Inspection
Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. See page 64.
CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
1. Remove the seat to access the engine compartment.
2. Remove the spark plug 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.

Spark Plugs

MAINTENANCE

Spark Plug Inspection

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 service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect throttle body/carburetor adjustments.

MAINTENANCE
Cooling System
The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator. Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.
66

Cooling System

MAINTENANCE

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. 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. See page 102 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 cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

Radiator and Cooling Fan
Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. 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 consequent engine damage.
NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a highpressure system is not recommended.

MAINTENANCE
Cooling System
Overflow Bottle Coolant Level
Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
The overflow bottle is located in front of the right front wheel.
1. Position the vehicle on a level surface.
2. View the coolant level in the overflow bottle.
3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid. Remove the cap and use a funnel to add coolant through the filler opening. Reinstall the cap.
Tip: If coolant must be added 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.

Overflow Bottle

Radiator Cap

Cooling System

MAINTENANCE

Radiator Coolant Level

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. 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 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 coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

Tip: This procedure is required only if the cooling system has been drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. See your dealer for the correct replacement part.

MAINTENANCE
POLARIS Variable Transmission (PVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:
· Always follow all recommended maintenance procedures. See your dealer as outlined 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.

When To Use Low Range vs. High Range
Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

Condition
Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h)

Range to Use
Low Low Low High

PVT System

MAINTENANCE

PVT Drying

There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain 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 belt slips, repeat the process.

8. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE
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 the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Disconnect the fuel pump wires.

3. Remove the spark plug.

4. Place a clean container under the engine and loosen the carburetor drain screw two turns.

5. Dry any water present in the air box. Filter replacement is required if water is present.

6. Thoroughly dry the air pre-cleaner located under the hood.

Drain Screw

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 drying procedure.

13. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

14. If water has been ingested into the PVT follow the procedure on page 71 for drying.

Filter Systems

MAINTENANCE

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

1. Lift the cargo box to access the air box.

2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.

Air Filter

3. Remove the air filter.

4. Do not attempt to clean the main element. Install a new air filter.

Tip: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.

5. Inspect the air box for 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.

MAINTENANCE
Filter Systems
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 filter.
3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace as needed.
4. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.
5. Reinstall the filter with the arrow pointing toward the engine. Secure the clamps.
NOTICE: Operation of the vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service.
74

Carburetor

MAINTENANCE

The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM is 1200 +/- 200.

Carburetor/Engine Idle RPM Adjustment
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 (counterclockwise) to lower RPM.

Idle Adjust Screw

MAINTENANCE
Spark Arrestor
WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time. Never go under the vehicle while it's inclined.
76

Spark Arrestor

MAINTENANCE

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.

1. Remove the arrestor clean-out plug located on the bottom of the muffler.

2. Place the transmission in PARK.
3. Start the engine.

Clean-Out Plug

4. Purge accumulated carbon from the system by momentarily revving the engine several times.

Exhaust Outlet

5. If carbon is expelled, cover or plug the exhaust outlet and rap on the pipe around the clean-out plug while revving the engine several more times.

6. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Block the wheels.

7. Repeat steps 4 and 5 until no more particles are expelled when the engine is revved.

8. Stop the engine. Allow the arrestor to cool.

9. Reinstall the arrestor plug and remove the outlet cover or plug.

MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.
Always check the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.

Throttle Freeplay
If the throttle pedal has excessive play due to cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.
Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Adjust the freeplay if necessary.

Throttle Pedal

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 (1.63.2 mm).

Throttle System

MAINTENANCE

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

3. Squeeze the end of the rub-

ber boot and slide it far

enough to expose the end

of the inline cable adjuster.

Boot

4. Loosen the adjuster lock

nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 78.

Lock Nut Adjuster

Tip: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

Cylinder Head/Cylinder Base Fastener Torque
Have your dealer check the cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.

MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 23.

Brake Fluid

Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. See page 55 for fluid recommendations.

1. Position the vehicle on a level surface.

Maximum Minimum

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.

Brakes
Brake Inspection
1. Check the brake system for fluid leaks.
2. Check the brake pedal for excessive travel or a spongy feel.
3. Check the friction pads for wear, damage and looseness.
4. Inspect the brake disc spline and pad wear surface for excessive wear.
5. Change pads when worn to 3/64" (1 mm).

MAINTENANCE
3/64" (1mm)

MAINTENANCE
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. 1. Position the vehicle on a level surface. 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 increase or decrease spring tension.
Cam
82

Tires

MAINTENANCE

WARNING
Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

1/8" (3 mm)

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 Nm) PLUS 1/4 TURN

Nut and Washer (Steel Wheels)
Spindle Nut Hub Retaining Nuts

Front and Rear 35 ft. lbs. (47 Nm)

Front Center and Rear

70 ft. lbs. (95 Nm) 110 ft. lbs. (150 Nm)

MAINTENANCE
Tires
Wheel Removal
1. Apply the brakes. 2. Place the transmission in PARK. 3. Stop the engine. 4. Loosen the wheel nuts slightly. 5. Elevate the side of the vehicle by placing a suitable stand under the
frame. 6. Remove the wheel nuts and washers. Remove the wheel.
Wheel Installation
1. Place the transmission in PARK.
2. Place the wheel in the correct 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 dealer.
3. Attach the wheel nuts and washers and finger tighten. 4. Carefully lower the vehicle to the ground. 5. Torque the wheel nuts to specification. See page 83.
84

Lights

MAINTENANCE

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement

1. Open the hood.
CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing.

Wiring Harness

2. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.

3. Turn the lamp counterclockwise to remove it.

4. Install the new lamp.

Tip: Make sure the tab on the lamp locates properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

MAINTENANCE
Lights
Headlight Beam Adjustment
X

X 8" (20 cm)

25 ft. (7.6 m)
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 the mark placed on the wall. Include the weight of a rider on the seat while performing this step. 5. If a headlight needs adjustment, access the adjustment screw under the hood or through the wheel well. 6. Loosen the screw, adjust the headlight, and tighten the screw. 7. Repeat steps 4-6 until the lamp is properly adjusted.

Lights

MAINTENANCE

Brake Lights

When the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the 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

Release

Tab

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 from the console panel.

4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4 turn counter-clockwise.

5. Grip the lamp with a needle-nose pliers and remove it from the assembly.

6. Install the new lamp. Using a screwdriver, rotate the lamp 1/4 turn clockwise to seat it.

7. Snap the assembly back into the console panel. Reconnect the harness.

8. Close the hood.

MAINTENANCE
Battery
WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, 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 and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery.
Tip: If accessories are using power constantly while the vehicle is operated in colder temperatures (below 30° F./-1° C.), a 30 amp/hour battery will provide the best performance, including improved starting performance.
88

Battery
Battery Removal

MAINTENANCE

WARNING
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

1. Remove the seat.

2. On conventional batteries, remove the battery vent tube.

3. Disconnect the black (-) battery cable first.

4. Disconnect the red (+) battery cable last.

5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

Battery

NOTICE: If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the 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 bat-
teries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.
4. Coat the terminals with dielectric grease or petroleum jelly. 5. Connect and tighten the red positive (+) cable first. 6. Connect and tighten the black negative (-) cable last. 7. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery. 8. Install the battery hold-down strap.
90

Battery

MAINTENANCE

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 92.

POLARIS recommends maintaining battery charge by using a POLARIS 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 102 for the part numbers of POLARIS products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Lower Mark

Add only distilled water. Tap water contains minerals that are harmful to a battery.

Upper Mark

MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 89.
2. Charge the battery with a charging output no larger than 1/10 of the battery's amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3. Reinstall the battery. See page 90. Make sure the positive terminal is toward the driver's side of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing 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 voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater. 3. When using an automatic charger, refer to the charger manufac-
turer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging.
92

Battery

MAINTENANCE

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

State of Charge
100%
75%-100%
50%-75% 25%-50% 0%-25%

Voltage 12.8-13.0 volts 12.5-12.8 volts
12.0-12.5 volts 11.5-12.0 volts 11.5 volts or less

Action
None, check at 3 mos. from date of
manufacture May need slight
charge, if no charge given, check in 3 months Needs charge Needs charge
Needs charge with desulfating charger

Charge Time
(Using constant current charger @ standard amps specified on top of battery)
None required
3-6 hours
5-11 hours At least 13 hours, verify state of charge At least 20 hours

MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.
NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots. Washing Tips · Avoid the use of harsh cleaners, which 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.
94

Cleaning and Storage

MAINTENANCE

Washing the Vehicle

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 labels. Avoid directing the water stream at the following items:

· Wheel bearings

· Radiator

· Transmission seals

· Brakes

· Cab and body panels

· Labels and decals

· Switches and controls

· Electrical components and wiring

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.

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.

Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.
Polishing Tips
· Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
· 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.

MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the 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 chrome wheels periodically. Use an automotive
grade chrome polish. 4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on 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.
96

Cleaning and Storage

MAINTENANCE

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 Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 94.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor.

4. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 58.

Air Filter / Air Box

1. Inspect and clean or replace the pre-cleaner and air filter. See page 73.

2. Clean the air box.

3. Drain the sediment tube.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 50.

Battery Maintenance

See pages 91-93 for storage and charging procedures.

MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 50. · Front and rear gearcase fluid (if equipped) · Transmission fluid · Brake fluid (change every two years and any time the fluid looks dark
or contaminated) · Coolant (test strength/fill) Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons (30-45 ml) of
engine oil. 2. Reinstall the spark plug. Torque to specification. See page 64. 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 97. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. 6. To eliminate any fuel remaining in the carburetor, run the engine until it stops. Storage Area/Covers Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
98

Removal from Storage

MAINTENANCE

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section on page 31. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer.
5. 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. Place the transmission in PARK. 3. Stop the engine. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the RANGER to the transporting unit
securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets. 6. Remove the key to prevent loss during transporting.

SPECIFICATIONS

RANGER 400

Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. Turning Radius Towing Capacity Max. Cargo Box Load Engine
Lubrication System Cooling Engine Oil Displacement Bore x Stroke (mm) Pilot Jet Main Jet Needle Jet Jet Needle Air Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug

1000 lbs. (454 kg)
1050 lbs. (476 kg) 8.8 gal. (33.3 l) 2 qts. (1.9 l) 2.25 qts. (2.4 l) 108 in. (274.3 cm) 56.5 in. (143.5 cm) 73 in. (185 cm) 72 in. (183 cm) 32 x 42 x 11.5 in. (81 x 107 x 29 cm) 10 in. (25.4 cm) 150 in. (381 cm) 1250 lbs. (567 kg) 500 lbs. (227 kg) 4 valve 4 stroke single cylinder with counter balance Dry Sump Liquid 0W/40 455 cc 87.9 x 75 42.5 150 P-6 (829) 4IB33 2.75 250 W 9.7:1 Electric 34 mm CDI 30° @5000 RPM NGK BKR6E

100

SPECIFICATIONS

Front Suspension Rear Suspension Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlights Taillights Brake Light Indicator Light

RANGER 400
Strut w/8 in. (20.3 cm) of travel Independent w/9 in. (23 cm) of travel PVT Single Lever (console) 7.70:1 7.00:1 4.12:1 3.818:1 25 x 8 - 12 25 x 11 - 12 10 psi (68.9 kPa) 12 psi (82.7 kPa) Foot Activated, 4 wheel hydraulic disc 2 single beam, 50W, quartz/halogen 10 L.E.D. (.28W) 10 L.E.D. (3.1W) 1.0 W

Clutching
See your POLARIS dealer for clutching specifications.

101

POLARIS PRODUCTS

Part Number
2870791 2876244 2876245
2878068 2878069 2877922 2877923 2871653 2872276 2870465
2871323 2871534
2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348
2871326 2870652 2872189 2871956 2871076

Description
Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 PLUS 2W-50 4-Cycle Oil (qt./.95 l) PS-4 PLUS 2W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants AGL PLUS Transmission Fluid (qt./.95 l) AGL PLUS Transmission Fluid (gal./3.8 l) Demand Drive Plus Fluid (qt./.95 l) Demand Drive Plus Fluid (gal./3.8 l) Premium ATV Angle Drive Fluid (8 oz./237 ml) Premium ATV Angle Drive Fluid (2.5 gal./9.5 l) Pump for Gallon (3.8 l) Jug
Coolant 60/40 Coolant (gal./3.8 l) 60/40 Coolant (qt./.95 l)
Grease / Specialized Lubricants Grease Gun Kit, Premium All Season Premium All Season Grease (3 oz./89 ml cartridge) Premium All Season Grease (14 oz./414 ml cartridge) Starter Drive Grease Premium U-Joint Lube (3 oz./89 ml cartridge) Premium U-Joint Lube (14 oz./414 ml cartridge) Dielectric Grease (NyogelTM) Chain Lube, Aerosol (6.25 oz.) Chain Lube, Aerosol (16 oz.)
Additives / Miscellaneous Carbon Clean Plus Fuel Stabilizer DOT 4 Brake Fluid LoctiteTM 565 Thread Sealant POLARIS Battery TenderTM Charger

102

TROUBLESHOOTING
Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures
Slow/easy clutch engagement Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow
Climbing over large objects from a stopped position
Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance
Slippage from failure to warm up belt
Wrong or missing belt Improper break-in

Use low range during loading.
Use low range. See warnings on page 37.
Drive at a higher speed or use low range more frequently. See page 70. Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Use the throttle quickly and effectively.
Use low range only.
Use low range only. Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn. 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 overturn. Dry out the PVT. See page 71. Inspect clutch seals for damage if repeated leaking occurs.
See your POLARIS dealer. Check for fouled plugs or foreign material in fuel tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing). Install the recommended belt. Always break in a new belt and/or clutch. See pages 29 and 70.

103

TROUBLESHOOTING
Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections

Recharge the battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Inspect, clean, reinstall connectors

Engine Turns Over, Fails to Start

Possible Cause
Out of fuel Water is present in fuel Old or non-recommended fuel Fouled or defective spark plugs No spark to spark plug Water or fuel in crankcase Overuse of choke Low battery voltage Mechanical failure

Solution
Refuel Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs and replace if necessary Immediately see your POLARIS dealer Inspect, clean and/or replace spark plug Recharge the battery to 12.8 VDC See your dealer

Engine Backfires

Possible Cause
Weak spark from spark plug Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure Loose ignition connections Water present in fuel

Solution
Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with fresh recommended fuel See your dealer See your dealer See your dealer Check all connections and tighten Replace with fresh recommended fuel

104

TROUBLESHOOTING
Engine Pings or Knocks

Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range

Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause
Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent line Incorrect fuel Clogged air filter Other mechanical failure
Possible Lean Fuel Cause
Overuse of choke Low or contaminated fuel Low octane fuel
Possible Rich Fuel Cause
Fuel is very high octane

Solution
Inspect, clean and/or replace spark plugs See your dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC Inspect and replace Replace with recommended fuel Inspect and clean or replace See your dealer
Solution
Inspect, clean and/or replace spark plug Add or change fuel, clean the fuel system Replace with recommended fuel
Solution
Replace with lower octane fuel

105

TROUBLESHOOTING
Engine Stops or Loses Power

Possible Cause
Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine

Solution
Refuel Inspect and replace Inspect, clean and/or replace spark plug Replace with new fuel Inspect, clean and/or replace spark plug See your dealer Set gap to specs or replace plug Check all connections and tighten Recharge the battery to 12.8 VDC Replace with fresh recommended fuel Inspect and clean or replace See your dealer Clean radiator screen and core, clean engine exterior, see your dealer

106

DECLARATION OF CONFORMITY
POLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010

We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES 2006/42/EC as amended (Machinery Directive)
2004/108/EC as amended (EMC Directive)

TEST / EVALUATION METHODS

EN 1050 hazard analysis prEN 15997 driver-perceived noise level prEN 15997 vibration

CISPR 12:2009 CAN/CSA-C108.4-M92

EN 55012:2007 EN 61000-6-2:2005

PRODUCT IDENTIFICATION

VEHICLE SERIES

TRADE NAME

___KA05__ / ___KA09__ ___FA09__ ___VA17__ ___PB20__ ___BA32__, ___NA32__ ___CA32__, ___EA32__ ___BA50__, ___BG50__ ___GJ45__ ___GJ52__, ___GP52__ ___LH46__ ___MH50__ ___DH50__ ___ZN55__ ___ZX55__ ___TN55__, ___TX55__ ___DN55__, ___DX55__ ___MN76__ ___CL76__, ___CF76__ ___ZN85__, ___ZX85__ ___TN85__, ___TX85__ ___DN85__, ___DX85__ ___RH45__ ___RH50__ ___TH76__ ___WH50__ ___WH76__ ___HR76__ ___HY76__, ___TY76__ ___TH90__ ___WH90__ ___VH76__, ___VY76__ ___XH76__

OUTLAW 50 / 90 SPORTSMAN 90 RZR 170 PHOENIX 200 TRAIL BLAZER 330 TRAIL BOSS 330 SCRAMBLER 500 OUTLAW 450 OUTLAW 525 / 525 S SPORTSMAN 400 SPORTSMAN 500 HO SPORTSMAN 500 HO TOURING SPORTSMAN 550 EFI SPORTSMAN 550 X2 SPORTSMAN 550 TOURING SPORTSMAN 800 SPORTSMAN 800 6X6 SPORTSMAN 850 EFI SPORTSMAN 850 X2 SPORTSMAN 850 TOURING RANGER 400 / 450 RANGER 500 4X4 RANGER 800 EFI 4X4 RANGER 500 CREW RANGER 800 EFI CREW RANGER 800 6X6 RANGER HD 800 4X4 RANGER DIESEL RANGER DIESEL CREW RANGER RZR / RZR S RANGER RZR 4

MODEL YEARS
2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2008, 2009, 2010, 2011 2010, 2011 2009, 2010, 2011 2010, 2011 2010, 2011 2008, 2009, 2010, 2011 2009, 2010, 2011 2009, 2010, 2011 2010, 2011 2010, 2011 2010, 2011 2010, 2011 2010, 2011 2011 2010, 2011 2010, 2011 2010, 2011 2011 2011 2008, 2009, 2010, 2011 2011

European Community Person Authorized to Compile the Technical File:
Ross Clifford, General Manager Polaris Britain Ltd Forge Mills Park, Station Road Coleshill, Warwickshire B46 1HT

Authorized Manufacturer Signatory Empowered to Draw up the EC Declaration of Conformity:
Lawrence E. Keller, Product Compliance Manager 7290 East Viking Blvd. Wyoming, MN 55092

107

WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a POLARIS dealer.

REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed 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 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 warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond POLARIS' control.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

· Wheels and tires · Suspension components · Brake components · Seat components · Clutches and components · Steering components · Batteries · Light bulbs/Sealed beam lamps

· Finished and unfinished surfaces · Carburetor/Throttle body components · Engine components · Drive belts · Hydraulic components · Circuit breakers/Fuses · Electronic components

108

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim:

· Spark Plugs · Filters · Fuel · Sealants · Hotel fees · Towing charges · Mileage · Rentals/Loss of product use

· Lubricants such as oil, grease, etc. · Batteries (unless defective) · Cosmetic damage/repair · Coolants · Meals · Shipping/ handling fees · Product pick-up/delivery · Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' 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 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 CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

109

WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.
Lubricants
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.
SPARK ARRESTOR
POLARIS warrants that the spark arrestor in this vehicle will meet the efficiency requirements of USFS standard 5100-1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
110

WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins.
How to Get Service
In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle. Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the 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. 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 obtain documentation from POLARIS Industries in order to register your vehicle in your new country. You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle.
111

WARRANTY
Exported Vehicles
How to Get Service
If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty.) For questions call POLARIS Customer Assistance: United States: 1-888-704-5290 Canada: 1-204-925-7100
112

WARRANTY
U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first.

This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

· Air-induction system · Fuel system

· Ignition system · Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

· Aftertreatment devices · Crankcase ventilation valves

· Sensors · Electronic control units

The following parts are considered emission-related components for evaporative emissions:

· Fuel Tank · Fuel Cap · Fuel Line · Fuel Line Fittings · Clamps* · Pressure Relief Valves* · Control Valves* · Control Solenoids* · Electronic Controls*

· Vacuum Control Diaphragms* · Control Cables* · Control Linkages* · Purge Valves · Vapor Hoses · Liquid/Vapor Separator · Carbon Canister · Canister Mounting Brackets · Carburetor Purge Port Connector

*As related to the evaporative emission control system.

113

WARRANTY
U.S.A. EPA Emissions Limited Warranty
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 LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO 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 CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workmanship.This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing competition. This limited 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 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 be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law. If you have any questions regarding your warranty rights and responsibilities, please contact the POLARIS Warranty Department at 1-888-704-5290.
114

MAINTENANCE LOG
Use the following chart to record periodic maintenance.

DATE MILES (KM) OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

115

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

116

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

117

INDEX
A
Accessory Outlet . . . . . . . . . . . . . . . 20 Air Filter . . . . . . . . . . . . . . . . . . . . . 73 All Wheel Drive . . . . . . . . . . . . . 47-48
Disengaging AWD. . . . . . . . . . 47 Locking the Differential . . . . . 48 All Wheel Drive Lock Switch . . . . . 21 Auxiliary Outlet . . . . . . . . . . . . . . . . 20 AWD . . . . . . . . . . . . . . . . . . . . . . 47-48 AWD/Differential Lock Switch. . . . 21 Axle Nut Torque . . . . . . . . . . . . . . . 83
B
Battery . . . . . . . . . . . . . . . . . . . . 88-93 Charging (Conventional) . . . . . 92 Charging (Sealed) . . . . . . . . 92-93 Fluid Replenishment . . . . . . . . 91 Installation . . . . . . . . . . . . . . . . 90 Removal. . . . . . . . . . . . . . . . . . 89 Storage . . . . . . . . . . . . . . . . . . . 91 Warnings . . . . . . . . . . . . . . . . . 88
Belt Life . . . . . . . . . . . . . . . . . . . . . . 45 Belt Wear . . . . . . . . . . . . . . . . . . . . 103 Brake Fluid . . . . . . . . . . . . . . . . . . . 80 Brake Inspection . . . . . . . . . . . . . . . 81 Brake Lights. . . . . . . . . . . . . . . . . . . 87 Brake Pedal . . . . . . . . . . . . . . . . . . . 23 Brakes . . . . . . . . . . . . . . . . . . . . . 80-81 Braking . . . . . . . . . . . . . . . . . . . . . . 33 Break-In Period . . . . . . . . . . . . . . 29-30 Breather Filter . . . . . . . . . . . . . . . . . 74
C
Cab Frame, ROPS . . . . . . . . . . . . . . 28 Cab Nets. . . . . . . . . . . . . . . . . . . . . . 26 Carburetor . . . . . . . . . . . . . . . . . . . . 75 Carburetor Adjustment . . . . . . . . . . 75 Cargo . . . . . . . . . . . . . . . . . . . . . . 42-43 Cargo Box, Dumping. . . . . . . . . . . . 44 Chrome Wheel Care . . . . . . . . . . . . 96 Cleaning and Storage. . . . . . . . . . 94-98 Cleaning the Exhaust System . . . . . 77 Cleaning the Spark Arrestor . . . . . . 77

C
Clutching . . . . . . . . . . . . . . . . . . . . . 101 Component Locations . . . . . . . . . 18-19 Console . . . . . . . . . . . . . . . . . . . . . . . 20 Coolant Level, Overflow Bottle . . . . 68 Coolant Level, Radiator. . . . . . . . . . . 69 Coolant, Adding or Changing . . . . . . 67 Cooling Fan . . . . . . . . . . . . . . . . . . . . 67 Cooling System . . . . . . . . . . . . . . 66-69 Corrosion Removal, Chrome. . . . . . . 96 Cylinder Head Fasteners . . . . . . . . . . 79
D
Differential Lock Switch . . . . . . . . . . 21 Differential Locking . . . . . . . . . . . . . 48 Disengaging AWD . . . . . . . . . . . . . . 47 Drive Belt Wear. . . . . . . . . . . . . . . . 103 Drivetrain Break-In . . . . . . . . . . . . . . 30 Driving Downhill. . . . . . . . . . . . . . . . 38 Driving in Reverse. . . . . . . . . . . . . . . 41 Driving on a Sidehill . . . . . . . . . . . . . 38 Driving on Slippery Surfaces . . . . . . 36 Driving Over Obstacles . . . . . . . . . . . 40 Driving Procedure . . . . . . . . . . . . . . . 34 Driving Through Water . . . . . . . . . . . 39 Driving Uphill . . . . . . . . . . . . . . . . . . 37 Driving with a Passenger. . . . . . . . . . 35 Driving, After Driving in Water . . . . 71 Dumping the Cargo Box . . . . . . . . . . 44
E
Emissions Limited Warranty . . 113-114 Engine Break-In. . . . . . . . . . . . . . . . . 30 Engine Fogging . . . . . . . . . . . . . . . . . 98 Engine Idle RPM Adjustment . . . . . . 75 Engine Oil . . . . . . . . . . . . . . . . . . 56-60 Engine Starting . . . . . . . . . . . . . . 32-33 Engine Stopping . . . . . . . . . . . . . . . . 33 Equipment Modifications . . . . . . . . . 13 Exhaust Cleaning. . . . . . . . . . . . . . . . 77 Exhaust System Warning. . . . . . . . . . 76

118

F
Fastener Torque Cylinder Head/Base . . . . . . . . . 79
Filter Change. . . . . . . . . . . . . . . . 58-60 Filter Systems . . . . . . . . . . . . . . . 73-74 Filter, Air . . . . . . . . . . . . . . . . . . . . . 73 Filter, Breather . . . . . . . . . . . . . . . . . 74 Filter, Fuel. . . . . . . . . . . . . . . . . . . . . 73 Fluid Change
Engine Oil . . . . . . . . . . . . . . 58-60 Front Gearcase . . . . . . . . . . . . . 63 Main Gearcase . . . . . . . . . . . . . 62 Transmission . . . . . . . . . . . . . . . 62 Fluid Level Coolant (Overflow Bottle) . . . . 68 Coolant (Radiator) . . . . . . . . . . 69 Engine Oil . . . . . . . . . . . . . . . . . 57 Front Gearcase . . . . . . . . . . . . . 63 Main Gearcase . . . . . . . . . . . . . 61 Transmission . . . . . . . . . . . . . . . 61 Fluid Levels During Storage. . . . . . . 98 Fluid Recommendation Coolant . . . . . . . . . . . . . . . . . . . 67 Engine Oil . . . . . . . . . . . . . . . . . 56 Gearcases . . . . . . . . . . . . . . . . . 61 Fluid, Battery . . . . . . . . . . . . . . . . . . 91 Fluid, Brake . . . . . . . . . . . . . . . . . . . 80 Fogging the Engine . . . . . . . . . . . . . . 98 Fouled Plugs . . . . . . . . . . . . . . . . . . . 65 Freeplay Adjustment, Throttle . . . . . 79 Freeplay Inspection, Throttle . . . . . . 78 Freeplay, Throttle . . . . . . . . . . . . . . . 78 Front Gearcase . . . . . . . . . . . . . . . . . 63 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 27 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73 Fuel Safety . . . . . . . . . . . . . . . . . . . . 15 Fuel Stabilizer . . . . . . . . . . . . . . . . . . 97

INDEX
G Gap, Spark Plug . . . . . . . . . . . . . . . . 64 Gasoline Handling . . . . . . . . . . . . . . 15 Gear Selector . . . . . . . . . . . . . . . . . . 22 Gearcase Specification Chart . . . . . . 61 Gearcase, Front . . . . . . . . . . . . . . . . . 63 Gearcase, Main . . . . . . . . . . . . . . 61-62 Gearcases . . . . . . . . . . . . . . . . . . 61-63 Gears, Shifting . . . . . . . . . . . . . . . . . 22
H Hauling Cargo. . . . . . . . . . . . . . . 42-43 Headlight Beam Adjustment. . . . . . . 86 Headlight Lamp Replacement . . . . . 85 Hitch Bracket . . . . . . . . . . . . . . . . . . 19 Hitch Weight. . . . . . . . . . . . . . . . . . . 45
I Idle RPM Adjustment . . . . . . . . . . . . 75 Ignition Switch . . . . . . . . . . . . . . . . . 21 Immersion of Vehicle . . . . . . . . . . . . 72 Indicator Light Replacement . . . . . . 87 Indicator Lights. . . . . . . . . . . . . . . . . 20
K Key, Periodic Maintenance Chart. . . 51
L Lamp Replacement, Indicator Lights 87 Light Switch . . . . . . . . . . . . . . . . . . . 21 Lights . . . . . . . . . . . . . . . . . . . . . 85-87
Brake Lights . . . . . . . . . . . . . . . 87 Headlight Beam Adjustment. . . 86 Headlight Lamp Replacement . 85 Indicator Lamp Replacement . . 87 Indicator Lights. . . . . . . . . . . . . 20 Lubrication Recommendations . . . . . 55

119

INDEX
M
Main Gearcase . . . . . . . . . . . . . . . 61-62 Maintenance Log . . . . . . . . . . . 115-117 Maintenance, Periodic . . . . . . . . . 50-54 Modifications. . . . . . . . . . . . . . . . . . 13
O
Obstacles . . . . . . . . . . . . . . . . . . . . . 40 Oil, Engine. . . . . . . . . . . . . . . . . . 56-60 Oil Change
Engine Oil . . . . . . . . . . . . . . 58-60 Front Gearcase . . . . . . . . . . . . . 63 Main Gearcase . . . . . . . . . . . . . 62 Transmission . . . . . . . . . . . . . . 62 Oil Level Engine Oil . . . . . . . . . . . . . . . . 57 Front Gearcase . . . . . . . . . . . . . 63 Main Gearcase . . . . . . . . . . . . . 61 Transmission . . . . . . . . . . . . . . 61 Oil Pump Priming . . . . . . . . . . . . . . 60 Oil Recommendations . . . . . . . . . . . 56 Operator Safety . . . . . . . . . . . . . . 10-17 Outlet, Auxiliary . . . . . . . . . . . . . . . 20
P
Parking on an Incline . . . . . . . . . . . . 46 Parking the Vehicle . . . . . . . . . . . . . 46 Periodic Maintenance Chart . . . . 50-54 Plug Gap . . . . . . . . . . . . . . . . . . . . . 64 Plug Torque . . . . . . . . . . . . . . . . . . . 64 Plug, Accessory . . . . . . . . . . . . . . . . 20 Plugs, Fouled . . . . . . . . . . . . . . . . . . 65 Polaris Products . . . . . . . . . . . . . . . 102 Polishing the Vehicle. . . . . . . . . . . . 95 Pre-Ride Inspection . . . . . . . . . . . . . 31 Pressure, Tire . . . . . . . . . . . . . . . . . . . 7 PVT Break-In. . . . . . . . . . . . . . . . . . 30 PVT Drying . . . . . . . . . . . . . . . . . . . 71 PVT System . . . . . . . . . . . . . . . . . 70-71

R
Radiator . . . . . . . . . . . . . . . . . . . . . . . 67 Radiator Coolant Level . . . . . . . . . . . 69 Reverse Operaton . . . . . . . . . . . . . . . 41 Roll-Over Protection System. . . . . . . 28 ROPS Cab Frame. . . . . . . . . . . . . . . . 28
S
Safety Labels . . . . . . . . . . . . . . . . . . 7-9 Safety Symbols . . . . . . . . . . . . . . . . . . 4 Safety Warnings . . . . . . . . . . . . . 14-17 Seat Belt Inspection . . . . . . . . . . . . . . 25 Seat Belts . . . . . . . . . . . . . . . . . . . 24-25 Seat Removal. . . . . . . . . . . . . . . . . . . 27 Severe Use Definition . . . . . . . . . . . . 50 Shifter . . . . . . . . . . . . . . . . . . . . . . . . 22 Shifting Gears . . . . . . . . . . . . . . . . . . 22 Shock Spring Adjustment . . . . . . . . . 82 Signal Words . . . . . . . . . . . . . . . . . . . . 4 Spark Arrestor . . . . . . . . . . . . . . . 76-77 Spark Arrestor Warning. . . . . . . . . . . 76 Spark Arrestor, Cleaning . . . . . . . . . . 77 Spark Plug Gap . . . . . . . . . . . . . . . . . 64 Spark Plug Inspection . . . . . . . . . 64-65 Spark Plug Recommendations. . . . . . 64 Spark Plug Torque . . . . . . . . . . . . . . . 64 Spark Plugs . . . . . . . . . . . . . . . . . 64-65 Spark Plugs, Fouled. . . . . . . . . . . . . . 65 Specifications. . . . . . . . . . . . . . 100-101 Specifications, Gearcase . . . . . . . . . . 61 Speed, Towing . . . . . . . . . . . . . . . . . . 45 Starting the Engine . . . . . . . . . . . 32-33 Steering Wheel Inspection. . . . . . . . . 82 Stopping the Engine. . . . . . . . . . . . . . 33 Storage . . . . . . . . . . . . . . . . . . . . . 94-98 Storage Area . . . . . . . . . . . . . . . . . . . 98 Storage Compartment . . . . . . . . . . . . 28 Storage Tips. . . . . . . . . . . . . . . . . 97-98 Storage, Battery . . . . . . . . . . . . . . . . . 91 Storage, Covers . . . . . . . . . . . . . . . . . 98 Storage, Removal From. . . . . . . . . . . 99

120

S
Switches AWD Switch. . . . . . . . . . . . . . . 21 Differential Lock Switch . . . . . 21 Ignition Switch . . . . . . . . . . . . . 21 Light Switch . . . . . . . . . . . . . . . 21
T
Throttle Freeplay. . . . . . . . . . . . . . . . 78 Throttle Freeplay Adjustment . . . . . . 79 Throttle Freeplay Inspection . . . . . . . 78 Throttle Pedal . . . . . . . . . . . . . . . . . . 23 Throttle System. . . . . . . . . . . . . . 78-79 Tire Pressure . . . . . . . . . . . . . . . . . . . . 7 Tires . . . . . . . . . . . . . . . . . . . . . . 83-84
Nut Torque . . . . . . . . . . . . . . . . 83 Tread Depth . . . . . . . . . . . . . . . 83 Wheel Installation . . . . . . . . . . . 84 Wheel Removal. . . . . . . . . . . . . 84 Towing Loads . . . . . . . . . . . . . . . . . . 45 Towing Speed . . . . . . . . . . . . . . . . . . 45 Trailer Hitch Bracket . . . . . . . . . . . . 19 Transmission . . . . . . . . . . . . . . . . 61-62 Transmission System . . . . . . . . . 70-71 Transmission, Drying . . . . . . . . . . . . 71 Transporting the Vehicle . . . . . . . . . 99

INDEX
V Vehicle Identification Numbers . . . . . 6 Vehicle Immersion . . . . . . . . . . . . . . 72 Vehicle Transport . . . . . . . . . . . . . . . 99
W Warning Symbols . . . . . . . . . . . . . . . . 4 Washing the Vehicle. . . . . . . . . . 94-95 Weight, Hitch . . . . . . . . . . . . . . . . . . 45 Wheel Installation . . . . . . . . . . . . . . . 84 Wheel Nut Torque . . . . . . . . . . . . . . 83 Wheel Removal . . . . . . . . . . . . . . . . 84

121

Acrobat Distiller 8.1.0 (Windows)