Polaris Ranger 400 HO User manual

Pantone 426C
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone]
Part No. 9922123 Rev 03
Printed in USA
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
NEVER Operate:
At speeds too fast for your skills or the conditions.
After or while using Alcohol or Drugs.
On hills steeper than 15 degrees 15 .
On public roads. A collision can occur with another vehicle.
With more than ONE passenger, or with a passenger under age
twelve or who cannot comfortably reach the floor and hand holds.
On paved surfaces - pavement may seriously affect handling
and control.
With non-Polaris approved accessories - they may seriously affect
stability.
Improper vehicle use can result in SEVERE INJURY or DEATH.
ALWAYS:
Wear your seat belt. Vehicle rollover could cause severe injury or
death.
Wear a helmet and eye protection and keep hands and feet in vehicle
at all times.
Reduce speed and use extra caution when carrying passengers.
Avoid sharp turns or turns while applying heavy throttle.
Operate slowly in reverse - avoid sharp turns or sudden braking.
Make sure passenger reads and understands all safety labels.
Watch for branches or other hazards that could enter vehicle.

WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.

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

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2
POLARIS, THE WAY OUT and RANGER are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are 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.
Printed in U.S.A.
2010 RANGER 400 HO Owner’s Manual
P/N 9922123

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Emission Control Systems . . . . . . . . . . . . . . . 47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 98
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 100
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 101
Declaration of Conformity . . . . . . . . . . . . . . . 105
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 112
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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

5
INTRODUCTION
Failure to follow the warnings contained in this manual can result in severe
injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle
handles differently than other vehicles, such as motorcycles and cars. A collision
or rollover can occur quickly, even during routine maneuvers like turning, or
driving on hills or over obstacles, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.
• This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you
are under age 16 and NEVER operate without a valid driver’s license.
• No person under the age of 12 may ride as a passenger in this vehicle. Any
passenger must be able to comfortably reach the floor and hand holds.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
WARNING

6
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: ___________________________________________________
(label on side of engine)
Key Number____________________________________________________________
VIN
Key
Number
####

7
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If any label becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety labels are provided by
Polaris at no charge. The part number is printed on the label.
Container/Passenger/Tire Pressure Warning
WARNING
• Passengers can be thrown off. This can cause
serious injury or death.
• Never carry passengers in cargo box.
Maximum Box Load 500 lbs. (227 kg)
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
FRONT TIRE - INFLATE TO 10 psi (68.9 kPa)
REAR TIRE - INFLATE TO 10 psi (68.9 kPa)
MAXIMUM WEIGHT CAPACITY INCLUDES
WEIGHT OF OPERATOR, PASSENGER,
CARGO AND ACCESSORIES. 1000 LBS. (455 kg)
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information. 7175941
+

8
SAFETY
Safety Labels and Locations
Age 16 Warning
Operating this vehicle if you are
under the age of 16 increases your
chance of severe injury or death.
NEVER operate this vehicle if you
are under age 16 and NEVER
operate this vehicle without a valid
driver’s license. 7175566
Shift Caution
CAUTION
To avoid transmission damage, shift
only when vehicle is stationary and
at idle.
APPLY BRAKE TO START. When
this vehicle is not in operation, or
unattended, place shift in the park
position. 7176170
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch
guard. To prevent serious injury, do
not operate vehicle with guard
removed.
• Do not modify engine or clutch. Doing
so can cause part failure, possible
imbalance, and excessive engine
RPM which can result in serious injury
or death. 7175488
Discretionary
Warning
Age 16
Warning Shift Caution
Clutch Cover
Warning

9
SAFETY
Safety Labels and Locations
Discretionary Warning
WARNING
Improper vehicle use can result in Severe Injury or Death.
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees 15°.
• On public roads, a collision can occur with a another vehicle.
• With more than ONE passenger, or a passenger under age twelve or who can-
not comfortably reach the floor and hand holds.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
ALWAYS:
• Wear your seat belt. Vehicle rollover could cause severe injury or death.
• Wear a helmet and eye protection and keep hands and feet in vehicle at all
times.
• Reduce speed and use extra caution when carrying a passenger.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passenger reads and understands all safety labels.
• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. 7176169

10
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 a passenger until you have at least two hours of driving
experience with this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle.
Any passenger must be able to comfortably reach the floor and hand
holds.
• The driver and any passenger must wear helmet, eye protection and
seat belt at all times.
• Always keep arms and legs inside the cab frame while the vehicle is
in motion.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Never consume alcohol or drugs before or while operating this
vehicle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your
experience.
• Never attempt jumps or other stunts.
WARNING

11
SAFETY
Operator Safety
• Always inspect your vehicle each time you use it to make sure it's in
safe operating condition. Always follow the inspection and
maintenance procedures and schedules described in this manual.
• Always travel slowly and use extra caution when operating on
unfamiliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning. Practice turning at slow
speeds before attempting to turn at faster speeds. Never turn at exces-
sive speeds.
• Always have this vehicle checked by an authorized Polaris dealer if it
has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for trav-
eling downhill and for braking on hills. Check the terrain carefully
before descending a hill. Never travel downhill at high speed. Avoid
going downhill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skid-
ding or sliding out of control.

12
SAFETY
Operator Safety
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.
• Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and fol-
low the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always place the transmission in PARK before getting out of the
vehicle.
• Always stop the engine before refueling. Make sure the refueling area
is well ventilated and free of any source of flame or sparks. Gasoline
is extremely flammable. See page 15 for fuel safety warnings.
• Always remove the ignition key when the vehicle is not in use to pre-
vent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-
342-3764.

13
SAFETY
Operator Safety
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris
RANGER any equipment that may increase the speed or power of the
vehicle, or make any other modifications to the vehicle for these pur-
poses. Any modifications to the original equipment of the vehicle create
a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris RANGER is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

14
SAFETY
Operator Safety
Failure to operate the RANGER properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
NEVER operate this vehicle if you are under
age 16 and NEVER operate without a valid
driver’s license.
No person under the age of 12 may ride as a
passenger in this vehicle. Any passenger
must be able to comfortably reach the floor
and hand holds.
Operating Without Instruction
Operating this vehicle without proper
instruction increases the risk of an accident.
The operator must understand how to
operate the vehicle properly in different
situations and on different types of terrain.
All operators must read and understand the
Owner's Manual and all warning and
instruction labels before operating the
vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of an accident or sudden stop. Riders must wear seat belts at
all times. Always make sure the seat belts are secured for both the operator and
passenger before riding.
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.
WARNING

15
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 inspect your RANGER before each use to make sure it's in safe
operating condition. Always follow all inspection and maintenance procedures
and schedules described in the owner's manual.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always stop the engine when refueling.
• Always refuel outdoors or in a well ventilated area.
• Remove flammable material containers from box before filling.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Operating at Excessive Speeds
Operating this vehicle at excessive speeds increases the operator's risk of
losing control. Always operate at a speed that's appropriate for the terrain, the
visibility and operating conditions, your skills and your passenger’s skills.

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