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Owner's Manual

for Maintenance and Safety

RANGER

Diesel HST

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.

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of

POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new

product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• ®RANGER utility vehicles

• ®RZR sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles

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.

POLARIS® and RANGER® are trademarks of POLARIS Industries Inc.

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.

2014 RANGER Diesel HST Owner’s Manual

P/N 9925451

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features And Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96. . . . . . . . . . . . . . . .

INTRODUCTION

This RANGER vehicle 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.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate

injury.

NOTICE

A NOTICE indicates a situation that could 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.

INTRODUCTION

Failure to follow the warnings contained in this manual can result in severe injury or death.

Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently

than other vehicles, such as cars, trucks or other off-road vehicles. 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. You MUST be at least age 16 and have a valid driver’s

license to operate this vehicle.

• All operators should take a training course.

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit

with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if

driving) or on a passenger hand hold.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all product

labels.

• Always keep hands, feet and all other body parts inside the vehicle at all times.

• Always wear the recommended safety gear.

• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce

operator reaction time.

WARNING

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

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________

Key Number: ________________________________________________________________________________

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery

is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

Engine Serial Number

Key

Number

####

VIN

SAFETY

Safety Gear

Always wear the proper clothing when operating or riding in this vehicle. All riders should

wear substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and

approved eye protection are recommended when appropriate for working or riding

conditions.

POLARIS recommends wearing approved eye protection bearing markings such as VESC 8,

V-8, Z87.1 or CE.

Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes.

Workplace safety regulations may require the use of safety glasses, safety shoes and a hard

hat or helmet. Familiarize yourself with local requirements, be prepared for operating

conditions and wear the appropriate safety gear.

Rider Comfort

Under certain operating conditions, heat generated by the engine and exhaust system can

elevate temperatures in the driver and passenger cab area. The condition occurs most

frequently when a vehicle is being operated in high ambient temperatures at low speeds and/

or high load conditions for an extended period of time. The use of certain windshield, roof

and/or cab systems may contribute to this condition by restricting airflow. Any discomfort

due to heat buildup in this area can be minimized by wearing proper riding apparel and by

varying speeds to increase airflow.

SAFETY

Safety and Information Labels

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.

Age 16 Warning

WARNING

No Operator Under 16

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

NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid

driver’s license.

To Start Engine / To Leave Vehicle

WARNING

To Start Engine

• Gear Selector must be in PARK, NEUTRAL, or treadle pedal must be in NEUTRAL.

To Leave Vehicle

• Put gear selector in PARK.

• STOP engine.

Maximum Trailer Weight Warning

WARNING

Towing An Improperly Loaded Trailer Can Cause Loss Of Control Resulting In Serious Injury Or Death.

Maximum Tongue Weight: 150 lbs. (68 kg)

Maximum Tow Weight: 2000 lbs. (907 kg)

See Operation & Maintenance Manual For More Instructions.

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.

Discretionary Warning

Age 16 Warning

Shift

Caution

To Start Engine /

To Leave vehicle

Rotating Fan Warning

Passenger/Tire Pressure

Warning

Towing

Warning

SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING

Improper vehicle use can result in Serious Injury or Death.

NEVER Operate:

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

• After or while using Alcohol or Drugs.

• Across slopes (avoid sidehilling).

• On public roads. This vehicle is for off-highway use only. Driving on public roads could be a violation

of law.

• With more passengers than described in the Owner’s Manual, with children under the age of 12, and

passengers who cannot comfortably reach the floor and hand holds with back against the seat.

• 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 serious injury or death.

• Keep hands and feet in vehicle at all times.

• Wear a helmet and eye protection.

• 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 passengers read and understand all safety labels.

Locate And Read Owner’s Manual. Follow All Instructions And Warnings.

Passenger/Tire Pressure Warning

WARNING

FALLING OFF CARGO BOX CAN CAUSE SERIOUS INJURY OR DEATH

• Never carry riders in cargo box.

WARNING

OVERLOADING OR IMPROPER TIRE PRESSURE CAN CAUSE TIPPING OR

LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Never exceed load capacities.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Carrying tall, off-center or unsecured loads will increase your risk of losing

control. Center and secure loads as low as possible in box.

• Reduce speed and cargo on rough or hilly terrain.

• Check for proper tire pressures.

Model RANGER Diesel HST

MAXIMUM CARGO BOX LOAD 1250 lbs. (567 kg)

TIRE PRESSURE IN PSI (KPa) Front 10 (69)

Rear 20 (138)

VEHICLE RATED CAPACITY

Includes weight of operator, passenger, cargo and accessories.

No Cab: 1750 lbs. (794 kg)

Cab: 1750 lbs. (794 kg)

READ OPERATION & MAINTENANCE MANUAL FOR DETAILED LOADING INFORMATION.

SAFETY

Operator Safety

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 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. All riders must be

able to sit with backs against the seat, both feet flat on the floor and both hands on the

steering wheel (if driving) or on a passenger hand hold.

• The driver and all passengers must wear appropriate safety gear and seat belt at all times.

• 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 rollover 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 (unless marked for off-

road use). 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.

• Always inspect the vehicle before each use to make sure it's in safe operating condition.

Always follow the inspection procedures 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. See page

37. Check the terrain carefully before attempting to climb a hill. Never climb hills with

excessively slippery or loose surfaces. Never apply throttle suddenly. Never make sudden

gear changes. Never go over the top of a hill at high speed.

WARNING

SAFETY

Operator Safety

• Always follow the proper procedures outlined in this manual for traveling downhill and

for braking on hills. See page 38. 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 large rocks or fallen trees. Always follow the proper procedures

outlined in this manual when operating over obstacles. See page 39.

• 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.

• Never operate your vehicle in fast-flowing water or in water deeper than that specified in

this manual. See page 40. 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 non-POLARIS-

approved 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. Remove flammable material containers from the

box before filling them with fuel. Make sure the refueling area is well ventilated and free

of any source of flame or sparks. Fuel is extremely flammable. See page 32 for fuel safety

warnings.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use

by someone under the age of 16 or without a driver’s license and proper training, or

accidental starting.

SAFETY

Operator Safety

Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover,

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.

Never operate with a passenger under the age of 12. All riders

must be able to sit with backs against the seat, both feet flat on

the floor and both hands on the steering wheel (if driving) or on a

passenger hand hold.

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.

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.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the

risk of serious injury in the event of rollover, loss of control, other

accident or sudden stop. Seat belts may reduce the severity of

injury in these circumstances.

All riders must wear seat belts at all times.

WARNING

SAFETY

Operator 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 perform the pre-ride inspection before each use of your vehicle to make

sure it's in safe operating condition. See page 29.

Always follow all inspection and maintenance procedures and schedules described in this owner's

manual. See page 46.

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of

others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the

instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the

specifications section of this manual and on a label on the vehicle. When more passenger weight is

added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications section of this manual and on a

label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions: Do ALL of these steps:

Passenger and/or cargo exceeds half the maximum

weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

SAFETY

Operator Safety

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 rollover or other accident, have a

qualified service dealer inspect the entire machine for possible damage, including (but not limited to)

seat belts, rollover protection devices, brakes, throttle and steering systems.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always

operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills

and your passengers’ skills and experience.

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow

proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp

angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster

speeds.

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 rollover.

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 (unless

designated for off-highway use). In some areas it's unlawful to operate this vehicle on public streets,

roads and highways.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover. 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 rollover.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or

rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing

terrain conditions.

SAFETY

Operator Safety

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 rollover. Do not operate on excessively slippery surfaces.

Always slow down and use additional caution when operating on slippery surfaces.

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction

unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this

owner's manual. See page 39.

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures

for climbing hills as described in this owner's manual. See page 37.

Descending Hills Improperly

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for

traveling down hills as described in this owner’s manual. See page 38.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause an rollover. Always maintain a steady

speed when climbing a hill.

If all forward speed is lost (engine running):

• Use the treadle pedal to slowly back the vehicle straight downhill.

• If necessary, apply brake pressure to control speed.

If all forward speed is lost (engine not running):

• Apply the brakes and attempt to restart the engine.

• If engine will not restart, place transmission in neutral and slowly allow the vehicle to roll straight

downhill while applying 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 operat e conditions on frozen bodies of water.ors assume all risk associated with ic

SAFETY

Operator Safety

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age

of 16, without a drivers license, or without proper training. This could result in an accident or rollover.

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, to avoid debris build-up around the

exhaust system.

Equipment Modifications

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose

of increasing speed or power. Any modifications or installation of non-POLARIS-approved

accessories could create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved

equipment and/or modifications have been added to the vehicle that increase 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.

For More Information About Safety, call POLARIS at 1-800-342-3764.

FEATURES AND CONTROLS

Component Locations

Not all models come with all features. See the specifications section beginning on page 86.

Occupant Protective Structure (OPS)

The Occupant Protective Structure (OPS) on this vehicle meets ANSI/OPEI B71.9-2012

occupant requirements. Always have your authorized POLARIS dealer thoroughly inspect

the OPS if it ever becomes damaged in any way.

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.

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and

property damage, always heed the warnings and towing capacities outlined on pages 41-42.

Front Bumper/

Brush Guard

OPS Cab Frame

Console Hip Bar

Cargo Box

Fuel Tank

Cap

Tailgate Latch

Release

Receiver Hitch

Muffler

(Spark Arrester)

Tailgate

Storage Compartment

Under Seats

Headlights

Taillights

Radiator

FEATURES AND CONTROLS

Switches and Indicator Lights

Ignition Switch

The ignition switch is a three-position, key-operated switch.

The key can be removed from the switch in the OFF position.

Mode Button

The button located on the instrument cluster is used to toggle through mode options. See

pages 22-27.

Power Lift Assist Switch (Box Dump Switch)

If equipped, use this switch to dump the cargo. See page 43.

OFF The engine is off. Electrical circuits are off, except Acc,

12V.

ON Electrical circuits are on. Electrical equipment can be

used.

START After the wait-to-start indicator turns off, turn the key to

the START position to engage the electric starter. The

key returns to the ON position when released.

Ignition Switch

Light Switch

Power Lift Assist Switch

(if equipped)

Accessory Switch

Openings

HVAC Switches

(if equipped)

Mode Button

AWD/Differential

Switch

START

OFF

FEATURES AND CONTROLS

Switches and Indicator Lights

Light Switch

The ignition switch must be in the ON position to operate

the headlights.

Press the top of the rocker switch toward the dash to place

the headlights on high beam.

Move the rocker switch to the center position to place the

headlights on low beam.

Press the bottom of the rocker switch to turn off the

headlights.

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock

Press the top of the rocker switch to engage All Wheel

Drive (AWD). See page 44 for operating instructions.

Move the rocker switch to the center position to lock the

differential and operate in rear wheel drive. Press the

bottom of the switch to unlock the differential and allow

the two rear drive wheels to operate independently. See

page 44 for differential lock operating instructions.

HVAC Switches (If Equipped)

If equipped with a Cab with HVAC (Heat and Air

Conditioning):

• Fan Switch (OFF-Low-Med-High)

• Air Conditioning (Press top of switch to turn Air

Conditioning ON, bottom for OFF)

• Temperature Control Switch (Rotate clockwise to

increase temperature, counter-clockwise to decrease)

Wiper Switch (If Equipped)

If equipped, the front wiper switch is located on the wiper

motor cover at the top of the front window.

• Wiper Switch (OFF-Low-High)

• Washer Switch (Press and hold top of switch to activate

window washer)

HIGH

OFF

LOW

AWD

Differential Lock

Differential Unlock

Fan A/C

On-O

Temp

Control

Wiper

Switch Washer

Switch

FEATURES AND CONTROLS

Auxiliary Outlets

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 dash.

Gear Selector

Use the gear selector to shift gears. Low gear is the primary driving range for the vehicle.

High gear is intended for use on hard-packed surfaces with light loads. To shift gears, brake

to a complete stop. When the engine is idling, move the lever to the desired gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause

transmission damage. Always shift when the vehicle is stationary and the engine is at idle.

Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your

dealer if you experience any shifting problems.

Adjustable Steering Wheel

The steering wheel can be tilted upward or downward for rider preference.

Lift and hold the adjustment lever toward you while moving the steering wheel upward or

downward. Release the lever when the steering wheel is at the desired position.

Brake Pedal

Depress the brake pedal to slow or stop the vehicle.

Apply the brakes while starting the engine.

Treadle Pedal

Use the treadle pedal to control the forward and reverse

movement of the utility vehicle. The farther the pedal

is pressed, the faster the travel speed.

Press the toe of the pedal for forward travel, press the

heel of the pedal for reverse travel.

Cup

Holder

12V Auxiliary

Outlets

Instrument

Cluster Gear Selector

(Shifter)

Storage

Compartment

Cup

Holder

Steering

Wheel

Adjustment

Lever

Treadle Pedal

Brake Pedal

FEATURES AND CONTROLS

Seat Removal

Pull up on the rear of the seat and tilt it toward the front of the vehicle. Install the seat by

sliding the tabs into the front of the seat base. Push down firmly on the rear of the seat until

the pins are fully seated into the grommets.

Seat Belts

This POLARIS vehicle is equipped with three-point lap

and diagonal seat belts on all seats. Always make sure the

seat belts are secured for all riders before operating.

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 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.

Buckle

Latch Plate

FEATURES AND CONTROLS

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle speed from the

transmission. In addition to showing vehicle speed, the speedometer needle flashes when a

warning condition exists.

NOTICE: High water pressure may damage components. Wash the vehicle by hand or with a garden

hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the instrument

cluster lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.

Do not allow insect sprays to contact the lens. Immediately clean off any fuel that splashes

on the instrument cluster.

Rider Information Center

The rider information display is located in the instrument cluster. All segments will light up

for 1 second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage

may have occurred and the instrument cluster may have shut off to protect the electronic

speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

1. Vehicle Speed (Speedometer) Display - Analog display of vehicle speed in MPH or

km/h.

2. Information Display Area - Odometer / Trip Meter / Tachometer / Engine

Temperature / Engine Hours / Service Info - LCD display of the service hour interval,

total vehicle miles or km., total engine hours, a trip meter, engine RPM and engine

temperature.

13 14

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the

Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode.

4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the

high beam position.

5. Fuel Level Indicator - LCD bar graph indicating current fuel level. All segments will

flash when the last segment is cleared indicating a low fuel warning.

6. Clock - Displays current time in either 12-hour or 24-hour formats.

7. Engine / Hydraulic Fluid Temperature Indicator - LED icon illuminates when the

ECM determines the engine is overheating. The indicators will initially flash to indicate

the engine is overheating. The indicators will stay lit and not ash if a severe

overheating condition exists.

8. Check Engine MIL - Illuminated when the ECM has detected a Diagnostic Trouble

Code in the engine management system.

9. Unit Lock - N/A on this model.

10. Hour Meter - Illuminates when the display (2) is showing hours.

11. Low Oil Pressure Indicator - LED icon illuminates low engine oil or hydraulic fluid

pressure is sensed.

12. Gear Position Indicator - Displays gear selector position.

H = High

L = Low

N = Neutral

P = Park

-- = Gear Signal Error (shifter stuck between gears)

13. Power Steering System MIL - N/A on this model.

14. Glow Plug Indicator - Illuminated when the glow plugs are active. Light goes out when

the engine is ready to start.

15. Seat Belt Indicator - LED icon illuminates for 10 seconds when the key is turned to the

ON position. The lamp is a reminder to the operator to ensure all riders are wearing seat

belts before operating the vehicle.

16. AWD/TURF Indicator - Illuminate to indicate how many drive wheels are active. This

will tell you if you are in AWD, 2WD, or Turf.

17. ADC Indicator - N/A on this model.

18. Service Interval Indicator - Preset at the factory and adjustable by the user, a flashing

wrench symbol alerts the operator that the preset service interval has been reached and

maintenance should be performed. The wrench icon will flash for 10 seconds upon start-

up once it reaches 0.

19. Unit of Measurement - Indicates the measurement (Trip 1, Trip 2, KM, MI, RPM)

being displayed in the Information Display Area (2).

FEATURES AND CONTROLS

Instrument Cluster

Information Display Area

The LCD portion of the instrument cluster is the information display area which displays the

following information: odometer, trip meter, RPM, battery voltage, engine temperature, air

temperature, engine hours, trouble codes, service interval, and clock.

Units of Measurement

To change between Standard and Metric units of measurement, follow these steps:

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to

the ON position.

3. When the display flashes the distance setting, tap the

MODE button to advance to the desired setting.

4. Press and hold the MODE button to save the setting and

advance to the next display option.

5. Repeat the procedure to change remaining display settings.

Odometer

The odometer records and displays the total distance traveled

by the vehicle. The odometer cannot be reset.

Trip Meter

The trip meter records the miles traveled by the vehicle on

each trip. To reset the trip meter:

1. Toggle the MODE button to TRIP 1.

2. To reset to 0, push and hold the MODE button until the

distance display changes to 0.

Engine Hours

Engine hours are logged anytime the engine is running. Total

hours cannot be reset.

Distance Miles (MPH) Kilometers (KM/H)

Temperature Fahrenheit Celsius

Time 12-Hour Clock 24-Hour Clock

FEATURES AND CONTROLS

Instrument Cluster

Information Display Area

Tachometer (RPM)

Engine RPM can be displayed digitally.

Engine Temperature

Engine temperature can be displayed in °F or °C. Refer to

“Units of Measurement” to change the format.

Clock

The clock displays the time in a 12-hour or 24-hour format.

Refer to “Units of Measurement” to change the format

(Standard 12-hour / Metric 24-hour). To set the clock, follow

these steps:

1. Toggle the MODE button until the odometer is displayed.

2. Press and hold the MODE button until the hour segment

flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10 minute and 1 minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

Battery Under / Over Voltage

This warning usually indicates that the vehicle is operating at an RPM too low to keep the

battery charged. It may also occur when the engine is at idle and a high electrical load is

applied (lights, cooling fan or other accessories).

Battery Voltage Low

If battery voltage drops below 11 volts, a warning screen will

display “Lo” and provide the present battery voltage. If

voltage drops below 8.5 volts, LCD back-lighting and icons

will turn off.

FEATURES AND CONTROLS

Instrument Cluster

Information Display Area

Programmable Service Interval

The initial factory service interval setting is 50 hours. Each

time the engine is started, the engine hours are subtracted

from the service interval hours. When the service interval

reaches 0, the LCD wrench icon will flash for approximately

10 seconds each time the engine is started.

To change the hour setting or reset the function, follow these

steps:

1. Toggle the MODE button until the wrench icon is displayed in the information area.

2. Press and hold the MODE button until the information display area begins to flash.

3. Toggle the MODE button to increase the service interval hours in 5 hour increments to a

maximum of 100 hours.

4. To turn off the service interval function, toggle the MODE button until “OFF” is displayed.

Check Hydraulic

This display indicates that hydraulic oil pressure is too low,

likely caused by a plugged line or by hydraulic oil

temperature being too high. The Oil or Temperature light will

illuminate along with this message.

FEATURES AND CONTROLS

Instrument Cluster

Information Display Area

Check Engine / Trouble Code Display

The diagnostic mode is accessible only when the check

engine MIL has been activated.

Use the following procedure to display diagnostic trouble

codes that were activated during current ignition cycle

causing the MIL to illuminate. Diagnostic trouble codes will

remain stored in the gauge (even if MIL turns off) until the

key is turned off.

1. If the trouble codes are not displayed, use the MODE button to toggle until “CK ENG”

displays on the information display area.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. A set of three numbers will appear in the information area.

4. The first number (located far left) can range from 0 to 9. This number represents the total

number of trouble codes present (example: 2 means there are 3 codes present).

5. The second number (located top right) can be 2 to 6 digits in length. This number

equates to the suspected area of fault (SPN).

6. The third number (located bottom right) can be 1 to 2

digits in length. This number equates to the fault mode

(FMI).

7. See your dealer for Diagnostic Trouble Codes.

8. If more than one code exists, press the MODE button to

advance to the next trouble code.

To exit the diagnostic mode, press and hold the MODE button

or turn the ignition key OFF once the codes are recorded.

Horsepower Management

Horsepower management automatically increases or decreases pressure to the hydrostatic

transmission to sustain engine RPM and maintain optimum drive performance.

The horsepower management system uses an adjustable spring to determine how much the

tractive eort is reduced under load to maintain optimal engine power.

The spring is factory adjusted to achieve a balance between maximizing travel performance

such as speed and acceleration characteristics and minimizing the amount of operator

modulation of the treadle pedal to reduce engine lugging or stalling under loads. The factory

adjustment also accounts for the additional engine load from the optional factory installed air

conditioning.

If less responsive horsepower management is desired (i.e. increased engine lugging during

operation) see your dealer for adjustment.

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover,

which may result in serious injury or death. Read and understand all safety warnings outlined in this

owner’s manual.

Break-In Period

The break-in period for your new vehicle is the first 50 hours of operation. No single action

on your part is as important as a proper break-in period. Careful treatment of a new engine

will result in more efficient performance and longer life for the engine.

New Engine Break-In

1. Fill the fuel tank with the recommended fuel. See page 30.

2. On the initial engine start-up, allow the engine to idle for approximately 15 minutes.

Check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks,

hydraulic leaks and proper operation of the indicators and gauges.

3. During the first hour of operation, vary engine speed and the load on the engine. Short

periods of maximum engine speed and load are desirable. Avoid prolonged operation at

minimum or maximum engine speeds and loads for the next 4 to 5 hours.

4. During the break-in period, carefully observe the engine oil pressure, engine temperature

and hydraulic fluid temperature.

5. Check the engine oil, engine coolant and hydraulic fluid level frequently during the

break-in period. Perform regular checks on areas outlined on the daily pre-ride

inspection checklist. See page 29.

6. Change both the engine oil and the filter at 50 hours.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation

and every 100 hours thereafter.

WARNING

OPERATION

Pre-Ride Inspection

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. 20, 66

Brake fluid Ensure proper level. 66

Front and Rear suspension Inspect, lubricate if necessary. 80

Seat Belts Check length of belt for damage, check latches for

proper operation. 21

OPS Check condition of OPS and mounting hardware. 21

Steering Ensure free operation. 68

Tires/wheels/fasteners Inspect condition and pressure. Inspect, ensure fastener

tightness. 74

Safety Labels Check for damaged or missing signs (decals). Replace

any signs that are damaged or missing. -

Frame nuts, bolts, fasteners Inspect, ensure tightness. -

Fuel and oil Ensure proper levels. 33, 52

Coolant level Ensure proper level. 57

Coolant hoses Inspect for leaks. -

Treadle Pedal Ensure proper operation. 20

Indicator lights/switches Ensure operation. 18

Air filter, pre-filter Inspect, clean and replace as needed. 60

Brake light/tail lamp /

Headlamp Check operation, apply POLARIS dielectric grease when

lamp is replaced. 75

Heater/Air Conditioning Filter Clean and replace filter as needed during heating and

cooling season. 71

OPERATION

Fuel Recommendations

NOTICE: For the best engine performance, to prevent engine damage and to comply with EPA/CARB

warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel

fuel.

POLARIS recommends the following diesel fuels for use in this vehicle:

• Low Sulfur

• Ultra Low Sulfur #2

• #1 Diesel Fuel containing no more than 5% bio-diesel (see page 31)

See page 33 for cold weather fuel blend recommendations. For more information about

recommended diesel fuels and the consequences of using bio-diesel fuel exceeding 5% bio-

diesel, see Additional Technical Fuel Requirements below.

Diesel fuel should comply with the following world-wide specifications.

Additional Technical Fuel Requirements

• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred.

Especially in the U.S.A. and Canada, Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low

Sulfur fuel should be used.

• Bio-Diesel fuels: see pages 31-32.

• NEVER mix kerosene, used engine oil or residual fuels with diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Poor quality fuel can reduce engine performance and/or cause engine damage.

• Fuel additives are not recommended. Some fuel additives may cause poor engine

performance.

• Ash content must not exceed 0.01% by volume.

• Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

• Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test

analysis method JPI-5S-44-95).

• Lubricity: Wear mark of WS1.4 should be Max. 0.018 in. (460µm) at HFRR test.

Diesel Fuel Specification Location

ASTM D975

No. 1D S15, S500

No. 2D S15, S500

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

KSM-2610 Korea

GB252 China

OPERATION

Fuel Recommendations

Bio-Diesel Fuels

B6 To B20 Bio-diesel Fuel Blend Usages

B6 to B20 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the YANMAR TNM engine series listed below may operate with bio-diesel fuel

concentrations up to B5 for POLARIS applications

NOTICE: Do not exceed bio-diesel fuel blend B5 for this POLARIS application.

• 3TNM72

Approved Fuel

NOTICE: Raw pressed vegetable oils are not considered bio-diesel, and are unacceptable for use as

fuel in any concentration in YANMAR engines.

Bio-diesel fuel blends up to B5 must comply with the following standards:

• EN14214 (European standard) and/or ASTM D-6751 (American standard).

• All applicable engines may operate with bio-diesel fuel up to a maximum B5 (5% bio-

diesel blend) concentration.

Operating Conditions with B5 Bio-diesel Fuel Blends

Engine Warranty

Damages, performance or service concerns determined to be caused by the use of bio-diesel

fuel not meeting the specifications outlined above are not considered to be defects in

material or factory workmanship and are not covered under warranty. The same applies to

damages or other concerns induced by not complying with the recommended operating

conditions of YANMAR engines with bio-diesel fuel.

Handling Fuel

WARNING! Diesel fuel is flammable and explosive under certain conditions.

• NEVER refuel with the engine running.

• Always refuel outdoors or in a well ventilated area.

• Fill the fuel tank with diesel fuel ONLY. Filling the fuel tank with gasoline may result in a fire and will

damage the engine.

• Remove flammable material containers from the box before filling them with fuel.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or

where fuel is stored.

• Wipe up all spills immediately.

• Keep sparks, open flames or any other form of ignition (match, cigarette, static electricity source)

well away when refueling.

• NEVER remove the fuel cap while the engine is running.

• NEVER overfill the fuel tank. Do not fill the tank neck.

• If fuel spills on your skin or clothing, immediately wash it off with soap and water and change

clothing.

OPERATION

Cold Weather Operation

Bio-Diesel Blended Fuel

NOTICE: Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle. See

page 31.

Bio-diesel blended fuel has unique qualities that should be considered before using it in this

vehicle:

• Cold weather conditions can lead to plugged fuel system components and hard starting.

• Bio-diesel blended fuel is an excellent medium for microbial growth and contamination

which can cause corrosion and plugging of fuel system components.

• Use of bio-diesel blended fuel may result in premature failure of fuel system components,

such as plugged fuel filters and deteriorated fuel lines.

• Shorter maintenance intervals may be required, such as cleaning the fuel system and

replacing fuel filters and fuel lines.

• Using bio-diesel blended fuels containing more than five percent (5%) bio-diesel can

affect engine life and cause deterioration of hoses, tubes, injectors, injector pump and

seals.

Use the following guidelines if bio-diesel blended fuel is used:

• Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle.

• Ensure the fuel tank is as full as possible at isture from collecting in all times to prevent mo

the fuel tank.

• Ensure that the fuel tank cap is securely tightened.

• Clean up any spilled fuel immediately to prevent damage to painted surfaces.

• Drain all water from the fuel filter daily before operating the vehicle.

• Do not exceed the engine oil change interval. Extended intervals can result in engine

damage.

• Before vehicle storage, drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel

stabilizer and run the engine for at least 30 minutes.

NOTICE: Bio-diesel blended fuel does not have long term stability and should not be stored for more

than three months.

OPERATION

Operating Conditions

NOTICE: Observe the following environmental operating conditions to maintain engine performance

and avoid premature engine wear.

• Avoid operating in the presence of chemical gases or fumes.

• Avoid operating in a corrosive atmosphere such as salt water spray.

• NEVER operate the engine in a floodplain unless proper precautions are taken to avoid

being subject to a flood.

• NEVER expose the engine to the rain.

• The standard range of ambient temperatures for the normal operation of YANMAR

engines is from +5° F (-15° C) to +104° F (+40° C).

• If the ambient temperature exceeds +104° F (+40° C), the engine may overheat and cause

the engine oil to break down.

• If the ambient temperature is between +5° F (-15° C) and -25° F (-32° C), POLARIS

recommends the use of a block heater.

Starting the Engine

NOTICE: NEVER use an engine starting aid such as ether. Engine

damage will result.

Before operating this vehicle in cold weather, review the cold

weather operation information beginning on page 33.

Always wait for the glow plug indicator light to turn off before

cranking the engine.

Tip: Engine will not start unless: Gear selector is in Park or Neutral, or

treadle pedal is in neutral.

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

2. Sit in the driver's seat and fasten the seat belt.

3. Apply the brakes.

4. Put the gear selector lever in the Park position.

5. Turn the ignition switch to the ON position and wait for the glow plug indicator light to

turn o before cranking the engine.

6. Turn the ignition switch past the ON position to START. Engage the starter for a

maximum of five seconds. Release the key when the engine starts.

7. If the engine does not start within five seconds, release the ignition switch and wait five

seconds. Repeat steps 5 and 6 until the engine starts.

8. Allow the engine to warm to operating temperature.

NOTICE: Operating the vehicle immediately after starting could cause engine and hydraulic

component damage. Allow the engine to warm up for several minutes before operating the

vehicle.

START

HELP

OPERATION

Stopping the Engine

For maximum engine life, allow the engine to idle, without load, for 5 minutes. This will

allow the engine components that operate at high temperatures, such as the exhaust system,

to cool slightly before the engine is shut down.

1. Press the brake pedal until the utility vehicle comes to a complete stop.

2. Move the gear selector lever to Park.

3. Turn the engine off and remove the key to prevent unauthorized use.

NOTICE: A rolling vehicle can cause serious injury. Always place the gear selector lever in PARK

before stopping the engine.

Braking

1. Release the treadle pedal completely.

2. Press the brake pedal evenly and firmly.

3. Practice starting and stopping (using the brakes) until you're familiar with the controls.

Tip: When the treadle pedal is released, the vehicle hydraulic system will gradually slow the vehicle to

a stop. Use the brake pedal for faster stopping.

Driving Procedure

1. Wear eye protection.

2. Perform the pre-ride inspection. See page 29.

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

4. Start the engine and allow it to warm up.

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

treadle pedal with your right foot to begin

driving. (Press the toe of the treadle pedal for

forward travel, press the heel of the treadle

pedal for reverse travel.)

8. Drive slowly. Practice maneuvering and using the treadle pedal and brakes on level

surfaces.

Tip: Allow the utility vehicle to come to a stop before changing directions with the treadle pedal.

9. Do not carry a passenger until you have at least two hours of driving experience with this

vehicle.

OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 29.

2. Make sure all passengers are 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 oor and

grasp the hand hold.

3. Make sure all passengers are wearing eye protection.

4. Make sure all passengers secure their seat belt.

5. Do not carry more than the recommended number of passengers for your vehicle. Allow

a passenger to ride only in a passenger seat.

6. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills,

and operating conditions. Avoid unexpected or aggressive maneuvers that could cause

discomfort or injury to a passenger.

7. Vehicle handling may change with a passenger and/or cargo on board. Allow more time

and distance for braking.

8. Always follow all operating guidelines as outlined on safety labels and in this manual.

Driving Uphill

Whenever traveling uphill, follow these precautions:

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.

5. Never climb hills with excessively slippery or

loose surfaces.

6. Proceed at a steady rate of speed. Never move the

treadle pedal or change direction of travel

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.

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or

rollover. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill (15° maximum).

15° maximum

OPERATION

Stalling While Climbing A Hill

Stalling or rolling backwards while climbing a hill could cause rollover. Always maintain a

steady speed when climbing hills.

If All Forward Speed Is Lost:

1. Apply the brakes.

2. Place the transmission in neutral and slowly allow the vehicle to roll straight downhill

while applying light brake pressure to control speed.

If you Begin Rolling Downhill:

1. Never apply engine power.

2. Decelerate using the treadle pedal and apply the brake gradually until the vehicle is fully

stopped.

3. Place the transmission in neutral and slowly allow the vehicle to roll straight downhill

while applying light brake pressure to control speed.

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.

Parking on an Incline

Avoid parking on an incline if possible. If it's

unavoidable, follow these precautions:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

15° maximum

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 hazards such as logs,

rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all

obstacles are immediately visible.

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind

the vehicle. Always inspect left and right fields

of vision before backing. Always look in the

direction of travel.

2. Always avoid backing downhill.

3. Back slowly.

4. Decelerate using the treadle pedal and apply the

brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never move the treadle pedal suddenly.

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or rollover (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.

WARNING

Sideways

skid

Turn in

direction of

skid

OPERATION

Hauling Cargo

Your RANGER has been designed to carry or tow specic capacities. Always read and

understand the load distribution warnings listed on the warning labels. The total load

(operator, passenger, attachments, accessories, cargo and weight on hitch) must not exceed

the maximum weight capacity of the vehicle. Never exceed the following capacities.

A - Weight of Occupant(s) = 500 lbs. (225 kg) Maximum

B - Maximum Cargo Box Load = 1250 lbs. (567 kg)

C - Maximum Trailer Hitch Tongue Weight = 150 lbs. (68 kg)

D - Tow Weight (Level Ground) = 2000 lbs. (907 kg) (includes weight of trailer)

Vehicle Rated Capacity: A + B + C = 1750 lbs. (794 kg)

Towing Loads

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 kg) tongue weight on the towing bracket.

2. Use low range. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

Towing a trailer increases braking distance.

3. Do not tow more than the recommended weight for the vehicle. See the towing capacity

chart on previous page.

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 Passenger Compartment Maximum

Cargo Box

Weight

Capacity

Maximum

Trailer Hitch

Tongue Weight

Vehicle

Rated

Capacity

Maximum

Weight Maximum

Occupants

RANGER Diesel HST 500 lbs.

(225 kg)

3 1250 lbs.

(567 kg)

150 lbs.

(68 kg)

1750 lbs.

(794 kg)

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 gear.

4. Engage the park brake.

5. Dismount the vehicle.

6. Ensure that the cargo is positioned evenly or

toward the front of the cargo box.

7. Release the tailgate by pulling up on the

tailgate latch.

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.

8. Stand clear and pull up on the cargo box release

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

cargo. If equipped with power lift assist, press and

hold the top of the lift switch to raise the cargo

box. Release the switch after cargo dumps or when

the box reaches the fully elevated position,

indicated by a ratcheting sound.

9. Lower the cargo box and push down securely to

latch. If equipped with power lift assist, press and

hold the bottom of the lift switch to lower the cargo

box. Release the switch when the box is fully

seated on the frame, indicated by a ratcheting

sound.

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.

Release Lever

Lift Switch

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 arrester that was tested and qualified to be in accordance

with the USFS standard 5100-1c. Federal law requires that this spark arrester 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/.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. A fuel injection system controls fuel

delivery. The engine and fuel injection components are set at the factory for optimal

performance and are not adjustable.

Your engine is designed to operate on low sulfur or ultra low sulfur diesel fuel only. Use of

any other fuel may result in your engine no longer operating in compliance with emissions

requirements.

Electromagnetic Interference

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 that apply to this

vehicle.

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. See page 94.

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 10 MPH (16 km/h). 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.

Maintenance Chart Key

►= 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.)

D= Caution: Due to the nature of these adjustments, it is recommended this service be

performed by an authorized POLARIS dealer.

Tip: Inspection may reveal the need for replacement parts. Always use genuine POLARIS parts.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

► Perform these procedures more often for vehicles subjected to severe use.

EEmission-Related Service

DHave an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

► Brake fluid level

- Daily - Check the levels and add as needed

► Coolant

► Diesel fuel level

►EEngine oil level

► Hydraulic oil level

► Brake system / pedal

travel

Daily Ensure proper operation

Engine speed control

lever (if applicable)

Treadle pedal

Headlights/Taillights

- Daily - Check for proper operation

Indicator lights/Switches

►EAir filter - Daily - Inspect filter element, replace as needed or

every 150 hours

►EAir intake sediment drains - Daily - Inspect drains on bottom of engine air

intake duct and air filter housing for

obstructions

► Cooling system - Daily - Inspect oil cooler, radiator A/C condenser (if

equipped) and grills for debris, remove

debris if needed.

Drive shaft boots Daily Inspect boots for damage, tears, ear or

leaking grease

EEngine intake pre-filter

screen (left side)

- Daily - Inspect; clean often

Frame fasteners Daily Inspect and ensure tightness

EFuel filter/water separator - Daily - Drain daily (severe conditions with poor fuel

quality) or every 50 hours (normal

conditions with quality fuel)

► Heater / A/C filter (if

equipped)

- Daily - Clean or replace filter as needed during

heating and cooling seasons

OPS - Daily - Check the condition of the OPS and

mounting hardware

Safety signs / Decals - Daily - Check for damaged signs (decals); replace

any that are damaged

Seat belts - Daily - Check the condition of the seat belts; clean

or replace seat belt retractors as needed

Steering / suspension - Daily - Inspect for broken parts, loose hardware

and free operation

Tires - Daily - Check for wear, damage and correct tire

pressure

Wheels/fasteners - Daily - Check for loose wheel nuts and tighten to

the correct torque value;

re-torque wheel nuts after 8 hours of use or

any time the nuts are removed for service

MAINTENANCE

Periodic Maintenance Chart

►Perform these procedures more often for vehicles subjected to severe use.

EEmission-Related Service

DHave an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first) Remarks

Hours Calendar Miles

(Km)

►Front gearcase lubricant

(Demand Drive Plus)

25 H 1 M 250

(400)

Initial fluid level inspection; add lubricant if

needed

►Transmission lubricant

(AGL Gearcase

Lubricant)

25 H 1 M 250

(400)

Initial fluid level inspection; add lubricant if

needed

►DBrake pad wear - 1 M 250

(400)

Initial fluid level inspection; add lubricant if

needed

DAlternator/Fan/Water

pump drive belt

50 H - - Check and adjust the V-belt after the initial

50 hours of operation; perform every 200

hours thereafter

DAir conditioning drive belt

(if applicable)

50 H - - Check and adjust the V-belt after the initial

50 hours of operation; perform every 200

hours thereafter

►

Engine oil & filter change 50 H - - Perform an oil and filter change after the

initial 50 hours of operation; perform every

100 hours or 6 months thereafter

Hydraulic / hydrostatic

system

50 H - - Replace hydraulic filter only after the initial

50 hours of operation; replace hydraulic

fluid, filter and reservoir breather cap every

400 hours thereafter

Battery 50 H 1 M - Check terminals; clean; test

EFuel filter / water

separator

50 H 3 M - Drain every 50 hours (normal conditions

with quality fuel) or daily (severe conditions

with poor fuel quality)

►General grease

lubrication

50 H 3 M 500

(800)

Lubricate all grease ttings, pivots, etc.

EAir intake ducts / adapters 50 H 6 M - Inspect ducts for proper sealing/air leaks

►EEngine oil & filter change 100 H 6 M - Perform an oil and filter change after the

initial 50 hours of operation; perform every

100 hours or 6 months thereafter

►Front / rear suspension 100 H 6 M 1000

(1600)

Inspect for wear

Shift cable / linkage 100 H 6 M 1000

(1600)

Inspect, lubricate, adjust

DSteering 100 H 6 M 1000

(1600)

Inspect steering freeplay

Travel Control And

Engine Speed Control

System

100 H 6 M 1000

(1600)

Inspect for proper operation and adjust if

necessary

►Cooling Hoses 100 H 12 M - Inspect for leaks; replace if necessary

►Engine mounts 100 H 12 M - Inspect, torque to specifications

Exhaust silencer/pipe 100 H 12 M - Inspect

D, E Fuel system 100 H 12 M - Check for leaks at fill cap, fuel lines and fuel

pump

MAINTENANCE

Periodic Maintenance Chart

►Perform these procedures more often for vehicles subjected to severe use.

EEmission-Related Service

DHave an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first) Remarks

Hours Calendar Miles

(Km)

DFront wheel bearings 100 H 12 M 1000

(1600)

Inspect; replace as needed

►Front Gearcase lubricant

(Demand Drive Plus)

100 H 12 M 1000

(1600)

Change lubricant

►Transmission lubricant

(AGL Gearcase

Lubricant)

100 H 12 M 1000

(1600)

Change lubricant

Hydraulic, hydrostatic and

power steering hoses

100 H 12 M 1000

(1600)

Inspect for damage and leaks; repair or

replace as needed

►Radiator 100 H 12 M 1000

(1600)

Inspect; clean external surfaces

►Wiring 100 H 12 M 1000

(1600)

Inspect for wear, routing, security; apply

dielectric grease to connectors subjected to

water, mud, etc.

Cooling system - 12 M - Test coolant strength and pressure test

system

►EAir filter 150 H - - Replace air filter; replace more often if

vehicle is subject to severe use

EFuel filter/water separator 150 H 12 M - Replace fuel filter / water separator

DAir conditioning drive belt

(if equipped)

200 H - - Check and adjust the V-belt after the initial

50 hours of operation; perform every 200

hours thereafter, replace as needed

DAlternator/Fan/Water

pump drive belt

200 H - - Check and adjust the V-belt after the initial

50 hours of operation; perform every 200

hours thereafter; replace as needed

DToe adjustment 200 H 24 M 2000

(3200)

Inspect; adjust if necessary or when parts

are replaced

DBrake fluid 200 H 24 M 2000

(3200)

Change every two years (DOT 4)

Spark arrester, exhaust

clean out

300 H 36 M - Remove plug and clean out

Hydraulic / hydrostatic

system

400 H - - Replace hydraulic uid, lter and reservoir

breather cap

D,E Engine valve clearance 1000 H Inspect and adjust as needed

►Coolant 1000 H 24 M - Replace coolant

D,E Fuel injectors 1500 H - - Inspect, clean and test fuel injectors, if

necessary

D,E Engine crankcase

breather system

1500 H - - Inspect crankcase breather system

►Fuel hoses 2000 H 24 M - Replace rubberized fuel hoses

►Cooling hoses 2000 H 24 M - Replace coolant hoses

Headlight aim - Adjust as needed

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance

Chart beginning on page 46, 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.

Start Interlock System

The utility vehicle is equipped with a Start Interlock

System. The following must be in place before the

engine can be started:

• the gear selector lever must be in Park or Neutral, or

• the treadle pedal must be in neutral

Inspection

To check the function of the Start Interlock System,

preform this procedure in an open area on level ground

and make sure the area is clear of bystanders.

1. With the gear selector lever in low gear, move the

treadle pedal to the forward travel position. The

engine must not start.

2. Repeat the procedure with the gear selector in High

and moving the treadle pedal into the reverse

direction.

3. If the engine starts in either of these positions, see

your dealer for service.

Item Lube Method

Engine Oil See page 52-53

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 66.

Main Gearcase Oil

(Transmission)

AGL Gearcase Lubricant &

Transmission Fluid

See page 54.

Front Gearcase Oil Demand Drive Fluid See page 55.

Front Prop Shaft

Yoke

U-Joint Grease Locate fittings and grease (3 pumps

maximum). See page 80.

Front and rear

suspension

U-Joint Grease Locate fittings and grease (3 pumps

maximum). See page 80.

Gear Selector Lever

Treadle Pedal

MAINTENANCE

Travel Direction And Engine Speed Control System

The travel direction control system requires regular inspection. See information below.

Inspect the travel direction control and engine speed control system to ensure proper

operation. Incorrect adjustment may cause erratic travel / engine speed conditions.

Failure to check or maintain proper operation of the travel control system can result in an accident and

lead to serious injury or death if the treadle pedal or the engine speed control lever sticks during

operation. Always inspect the treadle pedal for free movement and return to neutral before starting the

engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or

improperly operating treadle pedal. Immediately contact your dealer for service if travel control

problems arise.

Inspection And Maintenance

1. Position the utility vehicle on a level surface. Put the

gear selector in PARK and stop the engine. Exit the

utility vehicle.

2. Check the treadle pedal for excessive freeplay. The

correct amount of total free travel on the treadle pedal

is 0.30 in. (7.6 mm).

3. When on level ground, the gear selector lever in Park,

press the treadle pedal to full forward. Minimum

engine speed should be 3760 RPM. Repeat with

treadle pedal fully in reverse. Minimum engine speed

should be 3500 RPM.

4. If the treadle pedal does not return to neutral

unassisted during normal operation, see your dealer

for service.

WARNING

0.30 in.

(7.6 mm)

Treadle pedal

MAINTENANCE

Engine Oil

Always check the oil level daily. Change the engine oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 46. 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

NOTICE: Use of a non-recommended engine oil may cause serious engine damage.

POLARIS recommends the use of POLARIS Diesel Oil (SAE CI-4) for this vehicle. Always

use the correct viscosity grade based on the ambient temperature expected during operation.

See the chart below.

Oil Viscosity/Ambient Air Temperature Chart

Oil Check

The oil dipstick is located on the engine under the

passenger seat.

Tip: Engine oil should be checked cold or allow time for the

oil to drain back into pan before checking to prevent

overfilling.

1. Position the vehicle on a level surface.

2. Stop the engine.

3. Tilt the rear cargo box to access the engine oil

dipstick.

4. Remove the dipstick. Wipe it dry with a clean

cloth.

5. Reinstall the dipstick, then remove it and check the

oil level. Maintain the oil level in the safe range.

Do not overfill.

Tip: Due to the dipstick entry angle into the crankcase, the oil

level will read higher on the bottom side of the dipstick.

Always read the level on the upper surface of the

dipstick.

Safe

{

Safe

Range

Check Level

on Top Side

Dipstick

Add

MAINTENANCE

Gearcases

Gearcase Specification Chart

Transmission (Main Gearcase)

Always check and change the transmission oil at the

intervals outlined in the Periodic Maintenance Chart

beginning on page 46. Maintain the oil level even with

the bottom of the fill plug hole threads.

Refer to the Gearcase Specifications Chart for

recommended lubricants, capacities and torque

specifications. See page 85 for the part numbers of

POLARIS products.

Oil Check

The fill plug is located on the right side of the

transmission. Access the fill nd side of the vehicle. plug from the rear right-ha

1. Position the vehicle on a level surface. Remove the fill plug.

2. Check the oil level. Add the recommended oil as needed.

3. Reinstall the fill plug. Torque to specification.

Oil Change

The drain plug is located on the bottom of the transmission. Access the drain plug from

under the rear of the vehicle.

1. Remove the fill plug.

2. Place a drain pan under the vehicle at the location

of the drain plug.

3. Remove the drain plug. Allow the oil to drain

completely.

4. Clean and reinstall the drain plug. Torque to

specification.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque

Main Gearcase

(Transmission)

AGL Full Synthetic

Gearcase Lubricant &

Transmission Fluid

41 oz.

(1200 ml)

12 ft-lbs

(16.3 Nm)

12 ft-lbs

(16.3 Nm)

Front Gearcase Demand Drive Fluid 6.75 oz.

(200 ml)

8-10 ft-lbs

(11-13.6 Nm

8-10 ft-lbs

(11-13.6 Nm)

Fill Plug

Fill Level

Drain Plug

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 46. Maintain the oil level even with the bottom thread

of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 54 for recommended lubricants,

capacities and torque specifications. See page 85 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

1. Support the vehicle securely on jack stands.

2. Remove the fill plug.

3. Place a drain pan under the drain plug on the

bottom of the gearcase.

4. Remove the drain plug. Allow the oil to drain

completely.

5. Clean and reinstall the drain plug. Torque to

specification.

6. Add the recommended oil.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Dispose of used oil properly.

Fill Plug

Drain Plug

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.

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.

NOTICE: Do not mix different types of coolant in the cooling system when adding coolant. Mixing

types can result in damage to the cooling system.

POLARIS recommends the use of POLARIS Antifreeze 60/40 Premix or a 50/50 mixture of

high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS

antifreeze 60/40 is already premixed and ready to use. Do not dilute with water.

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 46. 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 ow 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 high-pressure 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 46. Maintain the coolant level between the minimum and maximum

marks on the bottle (when the fluid is cool).

The overflow bottle is located under the hood.

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 overow bottle

lid. Remove the cap and the rubber vented plug

and use a funnel to add coolant through the filler

opening. Reinstall the rubber vented plug and 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.

Radiator Coolant Level

1. Lift the hood.

CAUTION! Escaping steam can cause burns. Never

remove the pressure cap while the engine is warm or hot.

Always allow the engine to cool before removing the

pressure cap.

2. Slowly remove the radiator cap.

3. View the 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.

Maximum Minimum

Pressure Cap

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 floorboards.

2. Drain water from the intake drain valve and thoroughly dry the pre-filter box (located at

the left OPS post). See page 60.

3. Dry any water that is present in the air cleaner housing. Filter replacement is required if

water is present.

4. Remove the air intake resonator box and drain any water that is present. Dry the box

thoroughly.

NOTICE: If you believe water has entered the engine, Do Not start the engine. Engine damage will

result. Take the vehicle to your dealer before starting the engine.

5. Take the vehicle to your dealer for service as soon as possible, whether you succeed in

starting it or not.

6. Check the hydraulic fluid and differential fluid. If any indication of moisture is present,

replace the fluid and filters.

MAINTENANCE

Fuel Filter/Water Separator

The fuel filter/water separator is located under the

cargo box on the left side of the vehicle.

Inspect the separator daily for leaks. Drain water and

replace the separator at the intervals outlined in the

Periodic Maintenance Chart beginning on page 46.

Service the separator more frequently if the vehicle is

operated with poor quality fuel.

CAUTION! Both fuel and water will drain from the separator

during the following procedure. Use caution and observe all

fuel safety precautions when handling fuel.

1. Raise the cargo box.

2. Place an appropriate container under the fuel filter

drain to catch fluids (water and fuel).

3. Slightly loosen the bleed screw to relieve fuel pressure in the filter. Do not tighten the

screw at this time.

4. Reach under the fuel lter and slightly loosen the drain valve until the fluids drain from

the drain hole. Do not completely unscrew the drain valve.

5. When fluids stop draining from the valve, tighten

the valve firmly (by hand only).

6. Tighten the bleed screw.

7. With the gear selector in Park, turn the key to the

ON position. Do Not start the engine.

8. The fuel pump will start pumping fuel with the key

in the ON position (10 -15 seconds) and will force

air out of the fuel system.

9. At times it may be necessary to open the bleed

screw on the fuel filter housing until fuel comes

from the valve with no air bubbles.

10. Clean up any spilled fuel and soiled shop towels

properly.

11. Start the engine and check for fuel leaks.

12. Lower the cargo box.

Drain Valve Bleed Screw

Drain Hole

(viewed from bottom)

Tighten

Loosen

MAINTENANCE

Air Pre-Filter

Always clean the pre-filter at the intervals outlined in

the Periodic Maintenance Chart beginning on page 46.

Service the pre-filter more frequently if the vehicle is

operated in wet or dusty conditions or at high engine

RPM for extended periods.

The intake air pre-filter is located in the access panel

on the left rear OPS post. The pre-filter traps larger

particles before the air reaches the main engine air

filter.

Removal

1. Press the latch towards the front of the vehicle to

remove the pre-filter.

2. Clean debris from the pre-filter and inspect for

damage. If any damage is found, replace the pre-

filter assembly.

3. DO NOT use compressed air to clean the pre-filter

open. Use a damp cloth and clean the inside of the

pre-filter opening.

Installation

1. Insert the two tabs on the pre-filter assembly into

the side frame.

2. Rotate the pre-filter into the frame and make sure

the latch securely retains the pre-filter to it’s

original location.

Pre-Filter

Latch

Pre-Filter Housing

MAINTENANCE

Air Filter

Always change the air filter at the intervals outlined in

the Periodic Maintenance Chart beginning on page 46.

Service the air filter more frequently if the vehicle is

operated in wet or dusty conditions or at high engine

RPM for extended periods. Lift the cargo box to access

the air box.

1. Release the two air box cover clips. Remove the air

box cover.

2. Remove the air filter assembly with a pulling and

twisting motion. Use care to avoid damaging the

filter element.

NOTICE: Operating a diesel engine with a soiled or

damaged air filter can result in engine damage.

Do not attempt to wash the filter. Always replace a

soiled or damaged filter with a new filter.

3. Clean any dirt or deposits from the air box.

4. Reinstall the filter into the air box. Make sure it fits

tightly.

5. Install the cover and secure the with the two clips.

Clip ClipCover

Filter

Clean Air Box

MAINTENANCE

Cleaning Intake Water Drain Valve

1. Raise the cargo box.

2. An air intake water drain valve is located below the

pre-filter that should be inspected and clean at the

same time the pre-filter is cleaned.

3. Remove dirt and debris from the valve and squeeze

the valve to make sure it is not plugged. If any

damage is found, replace the drain valve.

Hydraulic/Hydrostatic System

Checking Fluid

WARNING! Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion

or fire.

1. Use only recommended fluid in the hydraulic system.

2. Park the utility vehicle on a level surface.

3. Put the gear selector in Park, stop the engine and

exit the vehicle. See page 36.

4. Raise the cargo box. See page 43.

5. Check the fluid level in the sight gauge. The fluid

level is correct when at the center of the sight

gauge.

6. Use only recommended POLARIS hydraulic fluid

when adding or changing the hydraulic fluid. See

page 85.

Adding Fluid

1. Clean the area around the fill cap.

2. If needed, remove the fill/breather cap and add fluid.

3. Lower the cargo box. See page 43.

Water Drain Valve

Sight Gauge Fill Cap

MAINTENANCE

Hydraulic/Hydrostatic System

Removing And Replacing Hydraulic/Hydrostatic Filter

Change the hydraulic/hydrostatic filter at the intervals outlined in the Periodic Maintenance

Chart beginning on page 46.

1. Park the utility vehicle on a level surface.

2. Put the gear selector in Park, stop the engine and

exit the vehicle. See page 36.

3. Raise the cargo box. See page 43.

4. Replace the fluid if it becomes contaminated or

after major repair.

5. Thoroughly clean the area around the fill cap.

6. Loosen the fill / breather cap to relieve hydraulic

system pressure.

WARNING! Diesel fuel or hydraulic fluid under pressure can

penetrate skin or eyes, causing serious injury or death. Fluid

leaks under pressure may not be visible. Use a piece of

cardboard or wood to find leaks. Do not use your bare hand.

Wear safety goggles. If fluid enters skin or eyes, get

immediate medical attention from a physician familiar with this injury.

7. Place a container under the filter. Recycle or

dispose of used oil in an environmentally safe

manner.

8. Remove the hydraulic filter.

9. Clean the surface of the filter housing where the

filter contacts the housing.

10. Put clean oil on the seal of the new filter. Install

and hand tighten.

11. Tighten the fill / breather cap.

12. Recycle or dispose of used fluid in an

environmentally safe manner.

WARNING! Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion

or fire.

13. Lower the cargo box. See page 43.

14. Start the engine. Stop the engine and check for leaks.

15. Check fluid level and add as needed. See page 62.

16. Use only recommended fluid in the hydraulic system. See page 85.

Fill/Breather Cap

Hydraulic/Hydrostatic Filter

MAINTENANCE

Hydraulic/Hydrostatic System

Removing And Replacing Hydraulic/Hydrostatic Fluid

Change the hydraulic/hydrostatic fluid at the intervals

outlined in the Periodic Maintenance Chart beginning

on page 46.

Replace the fluid if it becomes contaminated or after

major repair.

Always replace the hydraulic / hydrostatic filters

whenever the hydraulic fluid is replaced.

1. Move the gear selector lever to Park and stop the

engine. See page 36.

2. Raise the cargo box. See page 43.

3. Remove the clamp and the hose from the gear

pump fitting and drain the hydraulic fluid into a

container.

4. Thoroughly clean the area around the fill cap.

5. Slowly loosen the fill / breather cap to relieve

hydraulic system pressure in the tank. Remove the

fill / breather cap.

6. Remove and clean the hydraulic fill screen. Use

low air pressure to clean the screen.

7. Remove the hydraulic filter. see page 63. Install a

new filter.

8. Dispose of the used fluid in an environmentally

safe manner.

9. Install the fill screen and fill to the proper level.

See Page 64.

10. Install and tighten the fill / breather cap.

11. Lower the cargo box. See page 43.

WARNING! Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around, combustibles can cause

explosion or fire.

12. Start the engine and operate the hydraulic steering. If any hydraulic function operation is

not smooth, this may indicate that air is trapped in the hydraulic system. Continue to

operate the hydraulic steering until operation is smooth.

13. Stop the engine and check for leaks.

14. Check fluid level and add as needed.

HoseClamp

Fill Cap

Fill Screen

MAINTENANCE

Spark Arrester

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or

death.

Do not perform service on the spark arrester 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 can cause loss of consciousness or death in a very

short time.

Never go under the vehicle while it's inclined.

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

pipe.

1. Remove the arrester clean-out plug located on

the bottom of the muffler.

2. Place the transmission in Park. Start the

engine.

3. Press the brake pedal and then press the treadle

pedal to increase engine RPM. Purge

accumulated carbon from the system by

momentarily revving the engine several times.

4. If carbon is expelled, partially cover the

exhaust outlet and rap on the pipe around the

clean-out plug while revving the engine several

more times.

5. 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.

6. Repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

7. Stop the engine. Allow the arrester to cool.

8. Reinstall the arrester plug and remove the partial outlet cover.

WARNING

Clean-Out Plug

Exhaust Outlet

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See

page 20.

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 uid becomes contaminated, the

uid level is below the minimum, or if the type and brand of the uid in the reservoir are

unknown.

1. Position the vehicle on a level surface.

2. View the brake uid level at the reservoir in the

driver’s side wheel well.

3. The level should be between the upper (MAX) and

lower (MIN) level lines.

4. If the fluid level is lower than the upper level line,

add brake fluid to the upper (MAX) line.

5. Apply the brake forcefully for a few seconds and

check for fluid leakage around the fittings.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a

spongy feel.

3. Check the friction pads for wear, damage and

looseness.

4. Check brake discs for signs of cracks, excessive

corrosion, warping or other damage. Clean any

grease using an approved brake cleaner or alcohol.

NOTICE: Do not apply WD-40 or any petroleum product to

brake discs.

5. Inspect the brake disc spline and pad wear surface

for excessive wear. Change pads when worn to 3/64” (1 mm).

Maximum

Minimum

3/64” (1mm)

MAINTENANCE

Shift Cable Adjustment

Inspection

Shift cable adjustment is necessary when any of the

following is noticed:

• Noise on deceleration.

• Inability to engage a gear.

• Excessive gear clash (noise).

• Gear selector is moving out of desired range.

Inspect the shift cable, clevis pins, and pivot bushings

and replace if worn or damaged. Check the cable

adjustment per the following procedure.

WARNING! Stop engine and chock both rear tires before

inspecting or adjusting the shift cable.

1. Stop the vehicle on level surface, put the gear

selector in PARK and stop the engine.

2. Chock the wheels.

3. With the gear selector lever in the Park position. Make sure the lever is not contacting

the bottom of the shift slot.

4. Move the gear selector lever to the High position. Make sure the lever is not contacting

the top of the shift slot.

If there is any contact at either the bottom or the top of the gear selector shift slot, the shift

cable will need to be adjusted. Do the following adjustment:

1. Loosen the jam nuts.

2. Rotate the two jam nuts, as needed, to move the

gear selector lever up or down so the lever does not

contact the slot at either the bottom or top position.

3. Evenly tighten the two jam nuts until tight to the

cable mount.

4. Check operation of the gear selector. (Have the

vehicle in an open area with no bystanders or place

the vehicle on jack stands.) Start the engine. With

the gear selector in Park (the P light will be

illuminated), slowly increase the treadle pedal in

the forward direction. No utility vehicle movement

should occur and no gear clash noise detected.

Shift into High gear (the H light will be

illuminated), slowly increase the treadle pedal in

the forward direction to check forward travel. Shift into Low gear (the L light will be

illuminated), slowly increase the treadle pedal in the forward direction to check forward

travel. Move the gear selector to neutral (the N light will be illuminated), slowly increase

the treadle pedal in the forward direction. No utility vehicle movement should occur and

no gear clash noise detected.

If the gear selector lever and cable cannot be adjusted as indicated above, see your dealer for

service.

Top Shift Slot

Bottom Shift Slot

Jam Nuts

MAINTENANCE

Steering Wheel Inspection

Check the steering wheel for specied freeplay and smooth operation at the intervals

outlined in the Periodic Maintenance Chart beginning on page 46.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,”

have the steering system inspected by an authorized POLARIS dealer.

Suspension / Spring Adjustments

Adjust the rear and front shock absorber springs by rotating the adjustment cam either

clockwise or counter-clockwise to increase or decrease spring tension.

Cam

Rear Suspension Shown

Adjustment is similar for Front Suspension

MAINTENANCE

Alternator Belt

Belt Adjustment

Check the alternator belt at the correct service interval as outlined in the Periodic

Maintenance Chart beginning on page 46.

Stop the machine on a level surface. Put the gear selector in Park, stop the engine and exit the

vehicle. See page 36.

1. Raise the cargo box. See page 43.

2. Remove the three bolts and remove the shield.

3. The belt tension is correct with 5/16-1/2 in. (7-10

mm) of belt deflection at the mid span of the belt,

when 20 lbf (89 N) is applied to the belt.

4. If the belt tension is not correct, loosen the

mounting bolt and adjustment bolt.

5. Move the top of the alternator to tighten the belt.

6. Tighten the mounting bolt to 15 ft-lbs (20 Nm).

7. Tighten the adjustment bolt to 28 ft-lbs (38 Nm).

8. Install the shield and three bolts.

9. Lower the cargo box. See page 43.

Shield Bolt

Bolt

Mid Span

Adjustment Bolt Alternator

Mounting Bolt

MAINTENANCE

Alternator Belt

Belt Replacement

1. Loosen the mounting and adjustment bolts and move the alternator toward the engine.

2. Remove the belt.

3. Install the new belt and adjust as shown under Belt Adjustment.

Air Conditioning (if equipped)

Belt Adjustment

Check the air conditioning belt at the correct service interval as outlined in the Periodic

Maintenance Chart beginning on page 46.

1. Stop the machine on a level surface. Put the gear selector in Park, stop the engine and

exit the vehicle. See page 36.

2. Raise the cargo box. See page 43.

3. Remove the three bolts and remove the shield.

4. The belt tension is correct with 5/16-1/2 in. (7-10

mm) of belt deflection at the mid span of the belt,

when 20 lbf (89 N) is applied to the belt.

Shield Bolt

Bolt

Mid Span

MAINTENANCE

Air Conditioning (if equipped)

Belt Adjustment

5. If the belt tension is not correct, loosen the

mounting bolt and adjustment bolt.

6. Move the top of the compressor to tighten the belt.

7. Tighten the mounting bolt to 15 ft-lbs (20 Nm).

8. Tighten the adjustment bolt to 28 ft-lbs (38 Nm).

9. Install the shield and three bolts.

10. Lower the cargo box. See page 43.

Belt Replacement

1. Loosen the mounting and adjustment bolts and

move the compressor toward the engine.

2. Remove the belt.

3. Install the new belt and adjust as shown under Belt Adjustment.

Filter Cleaning

The air conditioning filter is located below the dash.

1. Remove the two fasteners and remove the filter

cover.

2. Clean the filter with low air pressure. Check for

damage, replace if damaged.

Adjustment Bolt

Mounting Bolt

Fasteners

Filter Cover

Filter

MAINTENANCE

Air Conditioning (if equipped)

Condenser Cleaning

If equipped with air conditioning, the condenser should be cleaned at the correct service

interval as outlined in the Periodic Maintenance Chart beginning on page 46.

1. Stop the machine on a level surface. Put the gear selector in Park, stop the engine and

exit the vehicle. See page 36.

2. Turn the two fasteners counter-clockwise 1/4 turn

and open or remove the cover.

3. Use low pressure air or water to clean the

condenser.

4. Close the door and turn the two 1/4 turn fasteners

clockwise.

Cover Fasteners

Condenser

MAINTENANCE

Supporting Utility Vehicle On Jack Stands

For service work under the utility vehicle, or to remove the wheels, always support the utility

vehicle with jack stands or blocks of adequate capacity for weight of utility vehicle. See

specifications page 86.

Always park the utility vehicle on a level surface. Put gear selector in Park, stop the engine

and exit the vehicle.

If removing wheel(s), loosen the wheel nuts slightly before lifting the vehicle.

WARNING! Instructions are necessary before operating or servicing machine. Read and understand

the Operator’s Manual, Operator’s Handbook (if equipped) and signs (decals) on machine. Follow

warnings and instructions in the manuals when performing repairs, adjustments or service. Check for

correct function after adjustments, repairs or service. Untrained operators and failure to follow

instructions can cause injury or death.

Place the jack stands under the front and rear frames of

the utility vehicle (both sides).

Tip: When lifting the utility vehicle, place jack under front and

rear frame.

Jack Stands

MAINTENANCE

Tires

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.

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.

Wheel Removal

1. Apply the brakes. Move the gear selector lever to PARK.

2. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the

wheel.

Wheel Installation

1. Apply the brakes.

2. Move the gear selector lever to PARK.

3. 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.

4. Attach the wheel nuts and washers and finger tighten.

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

Fastener Location Nut Torque

Wheel Nut Front and Rear 60 ft-lbs (81 Nm)

Spindle Nut Front 75 ft-lbs (102 Nm)

Hub Retaining Nuts Rear 110 ft-lbs (150 Nm)

WARNING

1/8”

(3 mm)

MAINTENANCE

Lights

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.

Brake Lights

When the brake pedal is depressed, the 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 0.4 in. (10 mm) of

pedal travel. If the light doesn't come on, check the rear light assembly.

Headlight Lamp Replacement

1. Open the hood.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing.

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

the wiring.

3. Turn the lamp counter-clockwise 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

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse or

relay may need replacement. Locate and correct any short circuits that may have caused a

blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.

If you suspect that a fuse or relay may not be

working properly, please see your POLARIS

dealer.

The fuse panel is located below the seat

between the operator and passenger. Remove

the seat.

Additional relays and fuses are also located in

the same area as the fuse and relay panels.

1. Relay = Radiator fan motor

2. Relay = HVAC (if equipped)

3. In-line fuse (30A) = HVAC (if equipped)

4. Circuit Breaker (40A) = Radiator fan motor

5. Circuit Breaker (20A) = Condenser fan

motor (if equipped)

MAINTENANCE

Battery

Improperly connecting or disconnec in an explosion and cause serious ting battery cables can result

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.

Your vehicle is equipped with a sealed battery, which

requires little maintenance. Always keep battery

terminals and connections free of corrosion. If cleaning

is necessary, remove 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.

Battery Removal

1. Remove the seat. The battery is located under the

passengers side of the vehicle.

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

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

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle.

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a

shorter life. It can also hinder vehicle performance. Follow the battery charging instructions

on page 78 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder. Install the battery hold-down strap.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the red (+) cable rst.

5. Connect and tighten the black (-) cable last.

WARNING

MAINTENANCE

Battery

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. 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 85 for the part

numbers of POLARIS products.

Battery Charging

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.

Always keep a sealed battery 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

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 manufacturer's instructions for

recharging. When using a constant current charger, use the guidelines below for

recharging.

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

State of

Charge Voltage Action

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no

charge given, check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours

25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify

state of charge

0%-25% 11.5 volts or less Needs charge with desulfating

charger

At least 20 hours

MAINTENANCE

Wheel Toe Alignment

Inspection

The wheel toe alignment requires regular inspection and maintenance at the correct service

interval as outlined in the Periodic Maintenance Chart beginning on page 46.

Stop the machine on a level surface. Put the gear selector in Park, stop the engine and exit the

vehicle. See page 36.

1. Turn the steering wheel so it is in the straight ahead position.

2. Place a chalk mark on the center of the front tires at

approximately 10 in. (254 mm) up from the floor

(or as close to the centerline of the front axle as

possible.

Tip: It is important that the height of both marks be equally

positioned to get an accurate measurement.

3. Measure the distance between the marks and

record this measurement. (We will call this

dimension A.)

4. Move the gear selector lever to Neutral and roll the

vehicle ahead until the chalk marks are to the rear of the front tires (approximately at the

centerline of the front axle). Move the gear selector lever to PARK.

5. Measure the distance between the chalk marks and record the dimension. (We will call

this dimension B.)

6. The difference between dimension A and B is the toe alignment. The recommended toe

tolerance is 0.125-0.25 inch (3.17-6.35 mm) toe out. (This means the measurement “A”

in front of the tire should be wider than the measurement “B” at the rear of the tire.

Toe Adjustment

Tip: Be sure the steering wheel is straight ahead before

determining which tie rod needs adjustment.

If the toe alignment is incorrect, measure the distance

between the center of the vehicle and each wheel. This

will determine which tie rod needs adjusting.

Tip: During tie rod adjustment, make sure to use a wrench on

both the tie rod end and the jam nut. Tie rod end damage

could occur if the tie rod end is not held securely while

loosening or tightening the tie rod jam nut.

1. Hold the tie rod end securely and loosen the jam

nut.

2. Use a wrench on the flat spot on the tie rod and a

wrench on the tie rod end. Rotate the tie rod to shorten or lengthen until the alignment is

as required to achieve the proper toe setting.

3. When alignment is correct, hold the tie rod end securely and tighten the jam nut to 14-16

ft-lbs (16-19 Nm) torque.

10 in.

254 mm

Chalk Mark

Place

MAINTENANCE

Lubricating The Utility Vehicle

Lubricate as outlined in the Periodic Maintenance Chart beginning on page 46.

Always use a good quality lithium based multi-purpose

grease.

Lubricate the following:

1. Lower A Arms (both sides)

2. Upper A Arms (both sides)

3. Trailing Arm - Rear Pivot (both sides)

4. Trailing Arm - Front Pivot (both sides)

MAINTENANCE

Lubricating The Utility Vehicle

5. Upper Suspension Arm

6. Drive Shaft (in front of transmission

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.

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:

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.

Lubricate all grease 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.

• Engine

• Air Intake

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Switches and controls

• Electrical components and wiring

MAINTENANCE

Cleaning and Storage

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.

Storage Tips

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 82.

Oil and Filter

Change the oil and filter. See page 53.

Air Filter / Pre-Filter

1. Inspect and clean or replace the pre-filter and air filter. See page 60.

2. Clean the air box, including sediment plugs.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic

Maintenance Chart beginning on page 46.

Battery Maintenance

See page 78 for storage and charging procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance

Chart beginning on page 46.

• Front gearcase fluid

• Transmission fluid

• Hydraulic/Hydrostatic fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

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.

Product specificaties

Merk:	POLARIS
Categorie:	Niet gecategoriseerd
Model:	Ranger Diesel HST (2014)

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