Polaris RANGER 2x4 User manual

1
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
Model Identification 1.2.......................
Serial Number Location 1.2...................
Models Numbers / Replacement Key 1.3.......
Machine Dimensions 1.4-1.5.....................
Specifications - RANGER 2X4 1.6-1.7.............
Specifications - RANGER 4X4 1.8-1.9.............
Specifications - RANGER 6X6 1.10-1.11.............
Publication Numbers 1.12.....................
Paint Codes 1.12.............................
Starting the RANGER 1.12.....................

GENERAL INFORMATION
1.2
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
Series Designation Basic Chassis
Designation Engine Designation
A11RF50AB
Emissions &
Model Option
Engine Designation Number
42 EH42PLE06 Single, L/C, SOHC 4 Stroke, Electric Start
50 EH50PLE16 Single, L/C, SOHC 4 Stroke, Electric Start
VIN Identification
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17
4XA R F 50A* 1P0 00 000
Vehicle Description Vehicle Identifier
Powertrain
Engine
Emissions Model
Year
Plant No.
Individual Serial No.
Body Style
Check Digit
World Mfg. ID
* This could be either
a number or a letter
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the flywheel housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
TRANSMISSION I.D. NUMBER
LOCATION
A
The transmission I.D. number is located
on the right side of machine.

GENERAL INFORMATION
1.3
MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION
The machine model number and serial number are
important for vehicle identification. The machine
serial number (A) is stamped on the lower frame
rail close to the front drive wheel. The model and
serial number (B) are also located on a sticker on
the hood liner.
REPLACEMENT KEYS
Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
B
31XX
Key Series
Number
A

GENERAL INFORMATION
1.4
MACHINE DIMENSIONS
58 in
147 cm
75 in
190.50 cm
13 in
23 cm
(Front of Box)
7.2 in
18 cm

GENERAL INFORMATION
1.5
MACHINE DIMENSIONS
120 in
305 cm
90 in
229 cm
48 in
152 cm
113 in
76 in
193 cm
7.2 in
18.25 cm
42 in
107 cm
33 cm

Lubricant Key
GENERAL INFORMATION
1.6
MODEL SPECIFICATIONS
MODEL: RANGER 2X4............
MODEL NUMBER: A11RB42AA...
ENGINE MODEL: EH42PLE06....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........
CDI Marking CU2570 Injector Oil N / A....... ..........
Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..
Ignition Timing 30qBTDC@5000RPMrq Transmission 27 oz (800 ml) PPS*..... .......
Spark Plug / Gap NGK BKR5E / 0.036I(0.9mm) Gearcase Oil (Front) N/A... .
Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) ....80-90...... .
Tail 5 watts Gearcase Oil (Middle) N/A........
Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......
Indicator ....1watt Brake(Foot) D.O.T. 3..........................
Voltage Regulator LR39..
Start System Electric start.......
DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........
Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......
Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..
Turning Radius 186I(472 cm) Gear Reduction-Hi 3.81:1..... ...
Toe Out 1/8I-1/4I(3-6.35 mm) Front Drive Ratio N/A........... ....
Ground Clearance 7.2I(180 mm) Middle Drive Ratio N/A.. ...
Front Vertical Travel 6.7I(170 mm) Final Drive Ratio 3.70:1....
Center Vertical Travel 5.25” (133 mm) Shift Type .........InLine EZShift Hi/Lo/Reverse
Rear Suspension Swing Arm w/Dual Shocks Brake Type: Hydraulic Foot Pedal... ........
Rear Travel 6.25I(158 mm) Parking Brake Foot Actuated (Mechanical)........ .......
Shock . . . (2)--2” Twin Tubes Front & Rear Brake Fixed Disc, Hydraulic....... ..
Shock Adjustment Cam Floating Caliper..
TIRES
Tire Size - Front 25 x 10 - 12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 8--12 psi.
Total Width 60I(152.40 cm)........
Total Length 113I(287 cm).......
Total Height 75I(190.50 cm)........
Wheel Base 76I(193 cm).......
Weight - Dry 1105 lbs. (412 kgs).......
LOAD CAPACITY
Tow Hitch Receiver Hitch.....................
Cargo Box Dimensions 58x42 x13 in...........
Cargo Box Load Capacity 850 lbs (317 kgs)......
*Payload Includes: One driver and two passengers
Hitch Tongue Capacity 75 lbs (28 kgs)..........
Hitch Towing Capacity 1400 lbs (523 kgs)..........
*Vehicle Payload 1500 lbs (681 kgs)...............

GENERAL INFORMATION
1.7
MODEL SPECIFICATIONS
MODEL: RANGER 2X4..........
MODEL NUMBER: A11RB42AA.
ENGINE MODEL: EH42PLE06..
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below 40qF+40_to +80_F
A
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5qC
+
4
0
t
o
+
8
0
F
+5_to +26_C
Meters 0--1800
1
4
0
1
3
5
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000) 140 135
(
F
e
e
t
)
1800--above
1
3
2
5
1
2
7
5
1
8
0
0
--
a
b
o
v
e
(6000-- above) 132.5 127.5
CLUTCH CHART
S
h
i
f
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D
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C
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n
C
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c
h
H
e
l
i
x
S
p
r
i
n
g
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Drriven Clutch
S
p
r
i
n
g
Helix Spring
A
n
g
l
e
A
l
t
i
t
u
d
e
Weight Spring Spring
p
g
Angle
Meters 0--1800 1
0
BH Bl
u
e
/
G
r
e
e
nBl
a
c
k41--
3
7
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000)
1
0
B
H
(5630511)
B
l
u
e
/
G
r
e
e
n
(7041157)
B
l
a
c
k
(7041782)
4
1
--
3
7
(5132344)
(
F
e
e
t
)
1800-3700 1
0
RH Bl
u
e
/
G
r
e
e
nBl
a
c
k41--
3
7
1
8
0
0
-
3
7
0
0
(6000-12000)
1
0
R
H
(5630515)
B
l
u
e
/
G
r
e
e
n
(7041157)
B
l
a
c
k
(7041782)
4
1
--
3
7
(5132344)
ENGINE
Type 4 Cycle, Single Cyl........................
Displacement 425 cc...............
Bore 3.46I(92mm).......................
Stroke 2.76I(75mm).....................
Valve Clearance In/Ex 0.006/0.006I@ TDC on compression.......
Compression Ratio 9.2 :1..........
Cooling Liquid....................
Lubrication Type Dry Sump............
Operating RPMr200 5250 RPM.........
Idle RPMr200 (lights off) 1200 RPM.....
Compression Pressure 70--90 psi.......
CARBURETION
Type BST 34 Mikuni CV................
Main Jet 135............
Pilot Jet 42.5.............
Jet Needle 4LC38--3...........
Needle Jet P--6 (829)...........
Pilot Screw 2.25 Turns..........
Pilot Air Jet 160..........
Valve Seat 1.2 Viton...........
Float Height 13mm (.51I).........
Fuel Octane (R+M/2) 87 Non-Oxygenated or.
89 Oxygenated
CLUTCH
Type PVT....................
Belt 3211077.....................
Belt Width (Projected) 1.188I(30.18mm).....
Drive Belt Deflection 1.125 “ (28.57 mm)......
Side Angle (Overall) 26q......
Outside Circumference 40.86 r.12I....
Center Distance 10” (254.5mm)..........
Clutch Offset 0.5I(12.7mm)............
Secondary Spring Black........
Driven Helix 41--37.............
Spring Position (Helix) .... 2
Spring Position (Sheave) 2..

GENERAL INFORMATION
1.8
MODEL SPECIFICATIONS
MODEL: RANGER 4x4............
MODEL NUMBER: A11RD50AA...
ENGINE MODEL: EH50PLE16....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........
CDI Marking CU2570 Injector Oil N / A....... ..........
Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..
Ignition Timing 30qBTDC@5000RPMrq Transmission 13.5 oz (400 ml) PPS*..... ....... ..
Spark Plug / Gap NGK BKR5E / 0.036I(0.9mm) GearcaseOil(Front) 5oz(150ml).... PDD*... .
Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) ....80-90...... .
Tail 5 watts Gearcase Oil (Middle) N/A........
Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......
Indicator ....1watt Brake(Foot) D.O.T. 3..........................
Voltage Regulator LR39..
Start System Electric start.......
DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........
Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......
Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..
Tow Capacity 1500 lbs. (680 kg) Gear Reduction-Hi 3.81:1...... ...
Turning Radius 150I(381 cm) Front Drive Ratio 3.83:1..... ....
Toe Out 1/8I-1/4I(3-6.35 mm) Middle Drive Ratio N/A........... ...
Ground Clearance 7.2I(180 mm) Final Drive Ratio 3.70:1.. ....
Front Vertical Travel 6.7I(170mm) ShiftType.........InLine EZShift Hi/Lo/Reverse
Center Vertical Travel 5.25” (133 mm) Brake Type: Hydraulic Foot Pedal........
Rear Suspension Swing Arm w/Dual Shocks Parking Brake Foot Actuated (Mechanical)... .......
Rear Travel 6.25I(158 mm) Front & Rear Brake Fixed Disc, Hydraulic........ ..
Shock . . . (2)--2” Twin Tubes Floating Caliper.......
Shock Adjustment Cam..
TIRES
Tire Size - Front 25 x 10 - 12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 8--12 psi.
Total Width 60I(152.40 cm)........
Total Length 113I(287 cm).......
Total Height 75I(190.50 cm)........
Wheel Base 76I(193 cm).......
Weight - Dry 1185 lbs. (442 kg).......
LOAD CAPACITY
Tow Hitch Receiver Hitch.....................
Cargo Box Dimensions 58x428x13 in..........
Cargo Box Load Capacity 1000 lbs (454 kgs)......
*Payload Includes: One driver and two passengers
Hitch Tongue Capacity 75 lbs (28 kgs)..........
Hitch Towing Capacity 1500 lbs (681 kgs)..........
*Vehicle Payload 1500 lbs (681 kgs)...............
Lubricant Key

GENERAL INFORMATION
1.9
MODEL SPECIFICATIONS
MODEL: RANGER 4X4..........
MODEL NUMBER: A11RD50AB.
ENGINE MODEL: EH50PLE16..
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below 40qF+40_to +80_F
A
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5qC
+
4
0
t
o
+
8
0
F
+5_to +26_C
Meters 0--1800
1
4
0
1
4
2
5
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000) 140 142.5
(
F
e
e
t
)
1800--above
1
3
2
5
1
2
7
5
1
8
0
0
--
a
b
o
v
e
(6000-- above) 132.5 127.5
CLUTCH CHART
S
h
i
f
t
D
r
i
v
e
C
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c
h
D
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i
v
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n
C
l
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c
h
H
e
l
i
x
S
p
r
i
n
g
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Drriven Clutch
S
p
r
i
n
g
Helix Spring
A
n
g
l
e
A
l
t
i
t
u
d
e
Weight Spring Spring
p
g
Angle
Meters 0--1800 1
0
MH Bl
u
e
/
G
r
e
e
nBl
a
c
k 4
0
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000)
1
0
M
H
(5630513)
B
l
u
e
/
G
r
e
e
n
(7041157)
B
l
a
c
k
(7041782)
4
0
(5131446)
(
F
e
e
t
)
1800-3700 1
0
WH Bl
u
e
/
G
r
e
e
nBl
a
c
k 4
0
1
8
0
0
-
3
7
0
0
(6000-12000)
1
0
W
H
(5630515)
B
l
u
e
/
G
r
e
e
n
(7041157)
B
l
a
c
k
(7041782)
4
0
(5131446)
ENGINE
Type 4 Cycle, Single Cyl........................
Displacement 499 cc...............
Bore 3.625I(92mm).......................
Stroke 2.955I(75mm).....................
Valve Clearance In/Ex 0.006/0.006I@ TDC on compression.......
Compression Ratio 10.2:1..........
Cooling Liquid....................
Lubrication Type Dry Sump............
Operating RPMr200 5250 RPM.........
Idle RPMr200 (lights off) 1200 RPM.....
Compression Pressure 70--90 psi.......
CARBURETION
Type BST 34 Mikuni CV................
Main Jet 142.5............
Pilot Jet 42.5.............
Jet Needle 4MB32--3...........
Needle Jet P--8...........
Pilot Screw 2.5 Turns..........
Pilot Air Jet 160..........
Valve Seat 1.2 Viton...........
Float Height 13mm (.51I).........
Fuel Octane (R+M/2) 87 Non-Oxygenated or.
89 Oxygenated
CLUTCH
Type PVT....................
Belt 3211077.....................
Belt Width (Projected) 1.188I(30.18mm).....
Drive Belt Deflection 1.125 “ (28.57 mm)......
Side Angle (Overall) 26q......
Outside Circumference 40.86 r.12I....
Center Distance 10” (254.5mm)..........
Clutch Offset 0.5I(12.7mm)............
Secondary Spring Black........
Driven Helix 40.............
Spring Position (Helix) .... 2
Spring Position (Sheave) 2..

Lubricant Key
GENERAL INFORMATION
1.10
MODEL SPECIFICATIONS
MODEL: RANGER 6x6............
MODEL NUMBER: A11RF50AA...
ENGINE MODEL: EH50PLE16....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........
CDI Marking CU2570 Injector Oil N / A....... ..........
Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..
Ignition Timing 30qBTDC@5000RPMrq Transmission 13.5 oz (400 ml) PPS*..... ....... ..
Spark Plug / Gap NGK BKR5E / 0.036I(0.9mm) GearcaseOil(Front) 5oz(150ml).... PDD*... .
Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) . . . 80-90...... .
Tail 5 watts Gearcase Oil (Middle) 6.75 oz (200 ml) 80--90........ ..
Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......
Indicator ....1watt Brake(Foot) D.O.T. 3..........................
Voltage Regulator LR39..
Start System Electric start.......
DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........
Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......
Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..
Tow Capacity 1500 lbs. (680 kg) Gear Reduction-Hi 3.81:1...... ...
Turning Radius 150I(381 cm) Front Drive Ratio 3.83:1..... ....
Toe Out 1/8I-1/4I(3-6.35 mm) Middle Drive Ratio 3.70:1........... ...
Ground Clearance 7.2I(180 mm) Final Drive Ratio 3.70:1.. ....
Front Vertical Travel 6.7I(170mm) ShiftType.........InLine EZShift Hi/Lo/Reverse
Center Vertical Travel 5.25” (133 mm) Brake Type: Hydraulic Foot Pedal........
Rear Suspension Swing Arm w/Dual Shocks Parking Brake Foot Actuated (Mechanical)... .......
Rear Travel 6.25I(158 mm) Front & Rear Brake Fixed Disc, Hydraulic........ ..
Shock . . . (2)--2” Twin Tubes Floating Caliper.......
Shock Adjustment Cam..
TIRES
Tire Size - Front 25 x 10 - 12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 8--12 psi.
Total Width 60I(152.40 cm)........
Total Length 120I(305 cm).......
Total Height 75I(190.50 cm)........
Wheel Base 90I(229 cm).......
Dry Weight. 1410 lbs. ( 526 kg).......
LOAD CAPACITY
Tow Hitch Receiver Hitch.....................
Cargo Box Dimensions 58x48x13 in...........
Cargo Box Load Capacity 1000 lbs (454 kgs)......
*Payload Includes: One driver and two passengers
Hitch Tongue Capacity 75 lbs (28 kgs)..........
Hitch Towing Capacity 1500 lbs (681 kgs)..........
*Vehicle Payload 1500 lbs (681 kgs)...............

GENERAL INFORMATION
1.11
MODEL SPECIFICATIONS
MODEL: RANGER 6x6..........
MODEL NUMBER: A11RF50AA.
ENGINE MODEL: EH50PLE16..
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below 40qF+40_to +80_F
A
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5qC
+
4
0
t
o
+
8
0
F
+5_to +26_C
Meters 0--1800
1
4
0
1
4
2
5
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000) 140 142.5
(
F
e
e
t
)
1800--above
1
3
2
5
1
2
7
5
1
8
0
0
--
a
b
o
v
e
(6000-- above) 132.5 127.5
CLUTCH CHART
S
h
i
f
t
D
r
i
v
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C
l
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c
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D
r
r
i
v
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n
C
l
u
t
c
h
H
e
l
i
x
S
p
r
i
n
g
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Drriven Clutch
S
p
r
i
n
g
Helix Spring
A
n
g
l
e
A
l
t
i
t
u
d
e
Weight Spring Spring
p
g
Angle
Meters 0--1800
G
Bl
u
e
/
G
r
e
e
n
S
ilv
e
r41--
3
7
M
e
t
e
r
s
(Feet)
0
--
1
8
0
0
(0--6000)
G
(5630514)
B
l
u
e
/
G
r
e
e
n
(7041157)
S
i
l
v
e
r
(7041499)
4
1
--
3
7
(5132344)
(
F
e
e
t
)
1800-3700 FBl
u
e
/
G
r
e
e
n
S
ilv
e
r41--
3
7
1
8
0
0
-
3
7
0
0
(6000-12000)
F
(5630515)
B
l
u
e
/
G
r
e
e
n
(7041157)
S
i
l
v
e
r
(7041499)
4
1
--
3
7
(5132344)
ENGINE
Type 4 Cycle, Single Cyl........................
Displacement 498 cc...............
Bore 3.625I(92mm).......................
Stroke 2.955I(75mm).....................
Valve Clearance In/Ex 0.006/0.006I@ TDC on compression.......
Compression Ratio 10.2:1..........
Cooling Liquid....................
Lubrication Type Dry Sump............
Operating RPMr200 5250 RPM.........
Idle RPMr200 (lights off) 1200 RPM.....
Compression Pressure 70--90 psi.......
CARBURETION
Type BST 34 Mikuni CV................
Main Jet 142.5............
Pilot Jet 42.5.............
Jet Needle 4MB32--3...........
Needle Jet P--8...........
Pilot Screw 2.5 Turns..........
Pilot Air Jet 160..........
Valve Seat 1.2 Viton...........
Float Height 13mm (.51I).........
Fuel Octane (R+M/2) 87 Non-Oxygenated or.
89 Oxygenated
CLUTCH
Type PVT....................
Belt 3211077.....................
Belt Width (Projected) 1.188I(30.18mm).....
Side Angle (Overall) 26q......
Outside Circumference 40.86 r.12I....
Drive Belt Deflection 1.125 “ (28.57 mm)......
Center Distance 10” (254.5mm)..........
Clutch Offset 0.5I(12.7mm)............
Secondary Spring Silver........
Driven Helix 41--37.............
Spring Position (Helix) ....1
Spring Position (Sheave) 1..

GENERAL INFORMATION
1.12
PUBLICATION NUMBERS
Model Model No. Owner’s
Manual PN Parts Manual PN Service Manual PN Parts Micro Fiche
PN
RANGER 2x4
RANGER 4x4
RANGER 6x6
A11RB42AA
A11RD50AA
A11RF50AA
9918176 99118179 9918071 9918180
When ordering service parts be sure to use the correct parts manual.
PAINT CODES
PAINTED
PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER
Springs Medium Gloss Black 9440 P--067
Hood/Dash Eddie Bauer Green 44931 P--195
Frame/Cab Medium Gloss Black 9440 / 8520147 P--067
Order direct from Midwest Industrial Coatings (952--942--1840). Mix as directed.
STARTING THE RANGER
NOTICE: To start theSeries 11 RANGER, the foot
brake must be depressed to start the machine. The
RANGER utilizes this safety feature to help prevent
any possible injury or accidents that may occur dur-
ing initial machine startup.
Brake Ignition Key
1. Press down on the foot brake. 2. Turn the ignition key to start the Ranger.

2
GENERAL INFORMATION
2.1
CHAPTER 2
MAINTENANCE
Periodic Maintenance Chart 2.2--2.3...............
Polaris Lubricant and Service Part Numbers 2.4.
Special Tools 2.5............................
Pre-Ride Inspection 2.5......................
Lubrication Charts 2.6-2.8........................
Front Gearcase Lubrication 2.9................
Middle Gearcase Lubrication 2.9--2.10..............
Rear Gearcase Lubrication 2.10--2.11................
Transmission Lubrication 2.11--2.12.................
Shift Linkage Adjustment 2.13..................
Throttle Pedal Inspection 2.14..................
Fuel System 2.14--2.17.............................
Battery Maintenance 2.17--2.18......................
Spark Plug / Electrical 2.18--2.19....................
Engine Coolant System 2.19--2.22...................
Air Filter / Breather Filter 2.22--2.24..................
Flywheel Housing 2.24........................
Oil Level and Filter Change 2.25--2.26................
Oil Pump Priming Procedure 2.26...............
Valve Adjustment 2.27--2.28.........................
Steering and Toe Alignment 2.28--2.29...............
Exhaust Pipe 2.30............................
Brake System 2.30--2.31............................
Wheel and Tire 2.31--2.32..........................
Suspension 2.32--2.33..............................

GENERAL INFORMATION
2.2
PERIODIC MAINTENANCE CHART
Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for
replacement parts. Always use genuine Polaris parts.
HCAUTION: Due to the nature of these adjustments, it is recommended that service be performed by
an authorized Polaris dealer.
"Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,
prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather
can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.
E Emission Control System Service
(California).
PERIODIC MAINTENANCE - ENGINE
Frequency
(Whichever comes first)
Item Hours Calendar Miles
(Km)
Remarks
E"Engine Oil - Level/Change 100 hrs 6 months N/A Check Level Daily; Break In service at 1 month
EOil Filter 100 hrs 6 months N/A Replace with oil change
E"Air Filter - Main Element Weekly Weekly N/A Inspect - Replace if necessary
"Air Box Sediment Tube -Daily N/A Drain deposits whenever visible
"Engine Breather Filter 25 hrs Monthly N/A Inspect and replace if necessary
"Oil Tank Vent Hose 100 hrs 12 months N/A Inspect hose routing /hose condition
EHValve Clearance 100 hrs 12 months N/A Inspect/Adjust
EIdle Speed As required As required N/A Adjust
Choke (Enricher) Cable 50 hrs 6 months N/A Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months N/A Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months N/A Inspect all ducts for proper sealing/air leaks
EHFuel System 100 hrs 12 months N/A Check for leaks at tank cap, lines, filter, pump &
carburetor. Replace lines every 2 years.
CHASSIS
Frequency
(Whichever comes first)
Item Hours Calendar Miles
(Km)
Remarks
EHFuel Filter 100 hrs 12 months N/A Replace filter annually
Coolant/Level Inspection Daily Daily N/A Replace engine coolant every 2 years
Coolant Strength / Pressure Test
System
100 hrs 6 months N/A Inspect strength seasonally; Pressure test sys-
tem annually
Radiator 100 hrs 12 months N/A Inspect / Clean external surface
Cooling System Hoses 100 hrs 12 months N/A Inspect
Engine Mounts 100 hrs 12 months N/A Inspect
Drain Recoil Housing Weekly Weekly N/A More often if operating in wet environment
Exhaust Muffler / Pipe 100 hrs 12 months N/A
ELECTRICAL
ESpark Plug 100 hrs 12 months N/A Inspect - Replace if necessary
Wiring 100 hrs 12 months N/A Inspect for abrasion, routing, security

GENERAL INFORMATION
2.3
CHASSIS
Frequency
(Whichever comes first)
Item Hours Calendar Miles
(Km)
Remarks
Ignition Timing 100 hrs 12 months N/A Inspect
Battery 25 hrs Monthly N/A Check terminals; Clean; Check fluid level
Headlight Aim As required As required N/A Adjust if Necessary
Headlamp Inspection Daily Daily N/A Check operation daily; Apply NyogeltGrease
to connector when lamp is replaced
Tail Lamp Inspection Daily Daily N/A Check Operation Daily; Apply NyogeltGrease
to socket when lamp is replaced
"General Lubrication 50 hrs 3 months N/A Lubricate All Fittings, Pivots, Cables, Etc.
"Front Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually
"Middle Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually
"Rear Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually
Drive Belt 50 hrs 6 months N/A Inspect - Adjust, Replace if Necessary
Clutches (Drive And Driven) 100 hrs 12 months N/A Inspect, Clean
"Transmission Oil Level 25 hrs Monthly N/A Inspect Monthly; Change Annually
Shift Linkage 50 hrs 6 months N/A Inspect,Lubricate, Adjust
HSteering 50 hrs 6 months N/A Inspect Daily, Lubricate
HToe Adjustment As required As required N/A Periodic Inspection, Adjust When Parts are Re-
placed
"Front Suspension 50 hrs 6 months N/A Inspect - Lubricate
"Rear Suspension 50 hrs 6 months N/A Inspect - Lubricate
Tires Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item
HBrake Fluid 200 hrs 24 months N/A Change Every Two Years
"Brake Fluid Level Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item
"Brake Lever Travel Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item
HBrake Pad Wear 25 hrs Monthly N/A Inspect Periodically
Auxiliary Brake Adjustment As required As required N/A Inspect Deflection Daily; Adjust
Brake System Pre-ride Pre-ride N/A Pre-Ride Inspection Item
Wheels Pre-ride Pre-ride N/A Pre-Ride Inspection Item
Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride N/A Pre-Ride Inspection Item
HCAUTION: Due to the nature of these adjustments, it is recommended that service be performed by
an authorized Polaris dealer.
"Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,
prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather
can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.
E Emission Control System Service
(California).

GENERAL INFORMATION
2.4
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871098 Premium 2 Cycle Engine Oil (Quart) (12
Count)
2871281 Engine Oil (Quart) Premium 4 Synthetic
0W--40 (4--Cycle) (12 Count)
2871844 Engine Oil (Gallon) Premium 4 Synthetic
0W--40 (4--Cycle) (4 Count)
2871567 Engine Oil (16 Gallon) Premium 4
Synthetic 0W--40 (4--Cycle)
Gearcase / Transmission Lubricants
2873603 Premium Synthetic Gearcase Lubricant (1
Gal.) (4 Count)
2873602 Premium Synthetic Gearcase Lubricant
(12 oz. bottle) (12 Count)
2871653 Premium Front Gearcase Fluid (8 oz.) (12
Count)
2871653 Premium Front Gearcase Fluid (2.5 Gal)
(2 Count)
2870465 Oil Pump for 1 Gallon Jug
2871654 Premium Drive Hub Fluid (8 oz.) (12
Count)
2872277 Premium Drive Hub Fluid (2.5 gal.) (2
Count)
2871653 AngleDriveFluid(8oz.)
Grease / Specialized Lubricants
2871322 Premium All Season Grease (3 oz.
cartridge) (24 Count)
2871423 Premium All Season Grease (14 oz.
cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
Additives / Sealants / Thread Locking Agents /
Misc.
2870585 LoctitetPrimer N, Aerosol, 25 g
2871956 LoctitetThread Sealant 565 (50 ml.) (6
Count)
2871949 LoctitetThreadlock 242 (50 ml.) (10
Count)
2871950 LoctitetThreadlock 242 (6 ml.) (12
Count)
2871951 LoctitetThreadlock 262 (50 ml.) (10
Count)
2871952 LoctitetThreadlock 262 (6 ml.) (12
Count)
2871953 LoctitetThreadlock 271 (6 ml.) (12
Count)
Part No. Description
2871954 LoctitetThreadlock 271 (36 ml.) (6
Count)
2870584 Loctitet680-Retaining Compound (10
ml.)
2870587 Loctitet518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
2872113 Disk Brake Quiet (12 oz.) (12 Count)
2871326 Premium Carbon Clean (12 oz.) (12
Count)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871957 Black RTV Silicone Sealer (3 oz. tube)
(12 Count)
2871958 Black RTV Silicone Sealer (11 oz.
cartridge) (12 Count)
2870990 DOT3 Brake Fluid (12 Count)
2872113 Disc Brake Quiet, Aerosol, (9 oz.) (12
Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
NOTE: Each item can be purchased separately at
your local Polaris dealer.

GENERAL INFORMATION
2.5
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
PA--44689 Valve Clutch Adjuster 2
2872105 Water Pump Mechanical Seal Puller 2
8712100 or 8712500 Tachometer 2,10
2200634 Valve Seat Reconditioning Kit 3
2870390 Piston Support Block 3
2871043 Flywheel Puller 3
2871283 Crankshaft/Water Pump Seal Install Kit 3
5131135 Water Pump Install Kit 3
2870569 Crankshaft Truing Stand 5
2872314 Carburetor Float Adjustment Tool 4
2870975 Mity VactPressure Test Tool 3, 4, 9
2870871 Ball Joint Replacement Tool 5
2870872 Shock Spanner Wrench 2, 5
2870623 Shock Absorber Spring Compression Tool 5
2871572 Strut Rod Wrench 5
2871573 LH Strut Spring Compressor 5
2871574 RH Strut Spring Compressor 5
2870506 Clutch Puller 6
9314177 Clutch Holding Wrench 6
2871358 Clutch Holding Fixture 6
2870341 Drive Clutch Spider Removal and Install Tool 6
2870654 Clutch Offset Alignment Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing Replacement Tool Kit 6
2870386 Piston Pin Puller 6
8700220 Clutch Compression Tool 6
2871025 Clutch Bushing Replacement Tool Kit 6
2872608 Roller Pin Removal Tool 7
8700226 CV Boot Clamp Pliers 7
PV--43568 Fluket77 Digital Multimeter 10
2870630 Timing Light 10
2870836 Battery Hydrometer 10
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
STires - check condition and pressures
SFuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
SAll brakes - check operation and adjustment (includes auxiliary brake)
SThrottle - check for free operation and closing
SHeadlight/Taillight/Brakelight - check operation of all indicator lights and switches
SEngine stop switch - check for proper function
SWheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are
secured by cotter pins
SAir cleaner element - check for dirt; clean or replace
SSteering - check for free operation noting any unusual looseness in any area
SLoose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
SEngine coolant - check for proper level at the recovery bottle

GENERAL INFORMATION
2.6
LUBRICATION
Item Lube Rec. Method Frequency*
1. Engine Oil
4-Strokes
Polaris 0W--40
Synthetic (PN
2871281)
Add oil to proper level. Change after 1st month, 6 months or 100
hours thereafter; Change more often (25-50
hours) in extremely dirty conditions, or short
trip cold weather operation.
2. Transmission Polaris Synthet-
ic Gear Case
Lubricant (PN
2871477)
Add lube to bottom of fill plug
threads.
Change annually. Change more often if used
in severe conditions.
3. Brake Fluid DOT 3 (PN
2870990)or
Dot 4
Fill reservoir between MAX and
Min lines.
As required. Change fluid every 2 years.
*More often under severe use, such as operated in water or under severe loads.
¡Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
©Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
Engine Oil and Filter
Transmission Brake Master Cylinder
1. Oil Filter
2. Fill Plug 3. Reservoir
Engine OIl Tank
1. Dipstick

GENERAL INFORMATION
2.7
LUBRICATION, CONT.
Item Lube Rec. Method Frequency*
4. Front Gearcase Polaris Demand Drive Hub Fluid
(PN 2871654)
Drain completely. Add lube to spe-
cified quantity.
Change annually©
5. Rear Gearcase Polaris Gear Drive Fluid
(PN 2871477)
Drain completely. Add lube to spe-
cified quantity.
Change annually©
6. Rear Prop
Shaft U--Joints
Polaris Premium U--Joint Lube
(PN 2871551)
Locate fittings and grease and
grease with grease gun.
Semi--annually¡
7. Rear Prop
Shaft Yoke
Polaris Premium U--Joint Lube
(PN 2871551)
Locate fittings and grease with
grease gun.
Semi--annually¡
8. Front Prop
Shaft U--Joints
Polaris Premium U--Joint Lube
(PN 2871551)
Locate fittings and grease with
grease gun.
Semi--annually¡
9. Front Prop
Shaft Yoke
Polaris Premium U--Joint Lube
(PN 2871551)
Drain completely. Add lube to spe-
cified quantity.
Semi--annually¡
10. Middle Gearcase Polaris Gear Drive Fluid
(PN 2871477)
Polaris Gear Drive Fluid Semi--annually¡
*More often under severe use, such as operated in water or under severe loads.
¡Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
©Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
Front Gearcase (4x4 & 6x6) Rear Gearcase (All Models)
Rear Prop Shaft Front Prop Shaft (4x4 & 6x6)
6. U--Joints 7. Yoke 8. U--Joints 9. Yoke
4. Fill Plug 5. Fill Plug
Drain Plug Drain Plug
10. Fill Plug
Drain Plug
MIddle Gearcase (6x6 )

GENERAL INFORMATION
2.8
LUBRICATION, CONT.
11. Hub Strut
Assembly
13. Swing
Arm Pivot
Front Hubstrut
Swingarm
Mid Angle Driveshaft (6x6)
12. Mid Axle Drive Shaft
Item Lube Rec. Method Frequency*
11. Hubsrut As-
sembly (Both
Sides)
Polaris All Season Grease
(PN 2871423)
Locate grease fitting on the underside of the hub-
strut assembly and grease with grease gun.
Semi Annually¡
12. Mid Axle
Drive Shaft (Both
Driveshafts) (6x6)
Polaris All Season Grease
(PN 2871423)
Locate grease two grease fittings on both ends
joints of driveshaft and grease with grease gun.
Locate grease fitting in center of driveshaft and
grease with grease gun.
Semi Annually¡
13. Swing Arm
Pivot
Polaris All Season Grease
(PN 2871423)
Locate grease fitting on inside of the swing arm
pivot.
Semi Annually¡
*More often under severe use, such as operated in water or under severe loads.
¡Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
©Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special