Polaris RANGER XP 900 User manual

PMS 419
Owner's Manual
for Maintenance and Safety
RANGER XP ® 900

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

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

PMS 419
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• If you are under age 16 and without a valid driver’s license.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees.
• On public roads, a collision can occur with another vehicle.
• With more than two passengers, or passengers under age
twelve or who cannot comfortably reach the floor and hand holds.
ALWAYS:
• Secure cab nets and keep hands and feet inside vehicle at all times.
• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-anke boots.
• Wear your seat belt. Vehicle rollover can cause severe injury or death.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Make sure passengers read and understand all safety labels.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
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. 9924098 Rev 02
Printed in USA

1
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.polarisindustries.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)
•RANGER®utility vehicles
• Victory Motorcycles®
• Low Emission Vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and recreational vehicles
manufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your POLARIS vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and rec-
ommendations in this owner’s manual. Your manual contains instructions for minor mainte-
nance, 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.

2
POLARIS, RANGER and RANGER XP are registered trademarks of POLARIS Industries Inc.
Copyright 2012 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 produc-
tion 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 liabil-
ity 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 origi-
nal instructions.
Printed in U.S.A.
2013 RANGER XP 900 Owner’s Manual
P/N 9924098

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4
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. You MUST be at least age 16 and have a valid driver’s
license to operate 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.
• Never permit a guest to operate this vehicle unless the guest has read this manual and all product
labels.
• Always use the cab nets while riding in this vehicle.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.
• Always keep hands and feet inside the vehicle at all times.
WARNING

5
INTRODUCTION
The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations con-
cerning 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.

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: ________________________________________________________________________
Key Number: ________________________________________________________________________________
Engine Serial Number
Key Number
VIN
####

7
INTRODUCTION
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

8
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.
Clutch Cover Warning
WARNING
Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY
or DEATH.
Always look for and remove debris inside and around clutch and vent system when replacing belt.
Read owner’s manual or see authorized POLARIS dealer.
7177469
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
Discretionary
Warning
Age 16
Warning
Shift
Caution
Clutch Cover
Warning

9
SAFETY
Safety Labels and Locations
Shift Caution
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is
stopped, place shift in parked position.
• APPLY BRAKE TO START
• If total payload is greater than 500 lbs. the vehicle must be operated in LOW range.
7178545
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 two passengers (five for CREW), or passengers under the age of twelve or who
cannot comfortably reach the floor and hand holds.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-POLARIS approved accessories - they may seriously affect stability.
ALWAYS:
• Wear your seat belt. Vehicle rollover could cause severe injury or death.
• Secure cab nets and 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.
7178544

10
SAFETY
Safety Labels and Locations
Load/Passenger/Tire Pressure Warning
Storage Box Load 250 lbs. (113 kg)
WARNING
• Passengers can be thrown off. This can cause serious
injury or death.
• Never carry passengers in cargo box.
IMPROPER TIRE PRESSURE OR OVERLOADING
CAN CAUSE LOSS OF CONTROL RESULTING IN
SERIOUS INJURY OR DEATH.
• 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.
7178618
RANGER 4 x 4
MAXIMUM CARGO BOX LOAD 1000 lbs.
(454 kg)
TIRE PRESSURE IN PSI (KPa) FRONT 10 (69)
REAR 12 (83)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO
AND ACCESSORIES
1500 lbs.
(682 kg)
Read Operation and Maintenance Manual for more detailed loading information.

11
SAFETY
Safe Riding Gear
Always wear appropriate clothing when
riding a POLARIS vehicle. Wear
protective clothing for comfort and to
reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe
head injury. Whenever riding this
POLARIS vehicle, always wear a helmet
that meets or exceeds established safety
standards.
Approved helmets in the USA and
Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05
label. The ECE mark consists of a circle surrounding the letter E,
followed by the distinguishing number of the country which has granted
approval. The approval number and serial number will also be displayed
on the label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS
vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield.
POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy over-the-ankle boots. Do not ride a POLARIS vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Helmet
Eye
Protection
Gloves
Over-the-Ankle Boots
Long
Pants
Long
Sleeves
E
4
051039
0006.31

12
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 all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times.
• Always use the cab nets while riding in this vehicle.
• Always keep hands and feet inside the vehicle at all times.
• Always keep both hands on the steering wheel and both feet on the floorboards of the
vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read this manual and all
product labels.
• To reduce tipover risk, be especially careful when encountering obstacles and slopes and
when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads. Always avoid paved
surfaces.
• Never consume alcohol or drugs before or while operating this vehicle.
• Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibil-
ity 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.
WARNING

13
SAFETY
Operator Safety
• 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 slip-
pery or loose surfaces. Never apply throttle suddenly. Never make sudden gear changes.
Never go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for traveling downhill and
for braking on hills. Check the terrain carefully before descending a hill. Never travel
downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles such as rocks or fallen trees. Always follow the proper procedures outlined
in this manual when operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly
and exercise caution to reduce the chance of skidding or sliding out of control.
• Never operate your vehicle in fast-flowing water or in water deeper than that specified in
this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving
water. If necessary, apply them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle when operating in
reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles
in reverse.
• Always use the proper size and type of tires specified in this manual. Always maintain
proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should be properly distrib-
uted 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. Gasoline is extremely flammable. See page 14 for fuel
safety warnings.
• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use
or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call
POLARIS at 1-800-342-3764.

14
SAFETY
Operator Safety
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS RANGER any equip-
ment that may increase the speed or power of the vehicle, or make any other modifications to
the vehicle for these purposes. Any modifications to the original equipment of the vehicle
create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your POLARIS RANGER is terminated if any equipment has been added to
the vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
POLARIS-approved accessories, and familiarize yourself with their function and effect on
the vehicle.
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 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 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.
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.

15
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.
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 an accident or sudden stop. Riders must wear
seat belts at all times. Seat belts reduce the severity of injury in the event of
a sudden stop or accident. Always make sure the seat belts are secured for both the operator and
passenger before riding.
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of
a serious injuries in the event of an accident.
Operator and all passengers must always wear an approved helmet that fits properly and eye
protection (goggles or face shield).
Cab Nets
Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event
of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and
feet inside the vehicle at all times.
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.
WARNING

16
SAFETY
Operator Safety
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:
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.
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.
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