2022 RANGER Diesel MD/ISRAEL Owner's Manual

Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider 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.

• 1 Helmet

• 2 Eye Protection

• 3 Long Sleeves

• 4 Gloves

• 5 Long Pants

• 6 Over-the-Ankle Boots

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.

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this 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.

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

Wear long sleeves and long pants to protect arms and legs.

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.

1 General Alert
2 Shift Alert

Read your owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Never use alcohol or drugs before or while driving or riding. Do not allow operation on public roads (unless designated for off-highway vehicle access). Wear approved helmet, goggles, and protective clothing. Always wear seat belts. Always use the cab nets or doors. Never exceed seating capacity.

Read the owner’s manual.
MAXIMUM DRAWBAR PULL: 3200 N ON LEVEL GROUND
MAXIMUM VERTICAL LOAD: 1700 N

Label Location: on the hitch receiver.

Read the owner’s manual.

Read your owner’s manual. Keep body parts away from belt.

1 Clutch Cover Alert

The Hot Liquid Warning label is located on the radiator.
WARNING
Hot liquids and steam may cause severe injury or burns. Allow the vehicle to cool before attempting to remove the radiator cap.

Part number: 7300427

• Never carry passengers in cargo box. Passengers can be thrown off. This can cause serious injury or death. Read owner's manual. NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

• 1 Label Location

• 

1. After entering the vehicle, insert the lower net rod into the net mount on the floor. Make sure the ball at the end of the rod is properly secured in the slot at the base of the mount.

2. Connect the latch at the top edge of the net to the receiver latch mounted on the front frame.

1. To exit the vehicle, release the top front latch.

2. Rotate the net rearward and slide the lower net rod out of the mount to remove it.

3. Allow the net to hang freely outside the vehicle while dismounting.

Use the rear hitch for towing a trailer. See the Hauling Cargo section for details and procedures.

The values given below pertain to factory-installed hitches and are provided for informational purposes only.

The hitch certification label is located near the hitch on models equipped with a factory-installed rear hitch.

1. To remove the hitch (if equipped), remove the cotter pin 1 and hitch pin 2. Remove the hitch, then reinstall the hitch pin 2 and secure the cotter pin 1.

2. To install the hitch, remove the cotter pin 1 from the hitch pin and remove the hitch pin 2.

3. Install the hitch to the receiver.

4. Reinstall the hitch pin (from the left side of the hitch) through the bore of both the receiver and the hitch.

5. Reinstall the cotter pin. Make sure the hitch assembly is secure at that the cotter pin is properly engaged over the hitch pin.

The 7-way trailer connector 1 installed on your vehicle meets the requirements of European standard ISO 1724.

This connector uses all 7 pins on newer model trailers. An older model trailer may not be compatible with this connector.

Improper electrical wiring changes can result in damage to both vehicle and trailer components. When in doubt about your trailer connection, please contact a qualified towbar specialist for assistance.

• 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, Ultra Low Sulfur fuel should be used.

• Bio-Diesel fuels.

• 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. 460μm (0.018 in.) at HFRR test.

In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.

These B20 diesel fuels must meet certain requirements:

1. The bio-fuels must meet the minimum specifications for the country in which they are used.

   • In Europe, bio-diesel fuels must comply with the European Standard EN14214.

   • In the United States, bio-diesel fuels must comply with the American Standard ASTMD-6751.2.

2. Bio-fuels should be purchased only from recognized and authorized diesel fuel suppliers.

Precautions and concerns regarding the use of bio-fuels:

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.

2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth.

3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures and poor injection nozzle spray atomization.

4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

5. Even bio-diesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system and/or fuel storage containers may be necessary.

6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

B21 To B100 Bio-diesel Fuel Blend Usage

B21 to B100 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the Kubota® engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applications.

• Kubota® 902D

Approved Fuel

Bio-diesel fuel blends up to B20 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 B20 (20% bio- diesel blend) concentration.

Operating Conditions with B20 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 Kubota® engines with bio-diesel fuel.

1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle.

2. Visit the Recreational Off-Highway Vehicle Association® web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA®.

3. Perform the pre-ride inspection.

4. Do not tow or carry cargo during this period.

5. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

6. The driver must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times.

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

8. Always make sure all cab doors are closed and latched when riding in this vehicle.

9. Place the transmission in PARK.

10. Start the engine.

11. Apply the brakes and shift into low gear.

12. Check your surroundings and determine your path of travel.

13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving.

14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

    WARNING

    Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

    • Avoid sharp turns.

    • Never turn while applying heavy throttle.

    • Never make abrupt steering maneuvers.

    • Operate at speeds appropriate for your skills, the conditions and the terrain.

    • DO NOT do power slides, “donuts”, jumps or other driving stunts.

• Perform the pre-ride inspection.

• 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 floor and grasp the hand hold.

• Make sure all passengers are wearing helmets, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

• Make sure all cab nets or doors (if equipped) are properly secured.

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

• Allow a passenger to ride only in a passenger seat.

• 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.

• Vehicle handling may change with a passenger and/or cargo on board. Allow more time and distance for braking.

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

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions:

• Do not operate on excessively rough, slippery or loose terrain.

• Slow down before entering slippery areas.

• Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

• 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.

• Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

Follow these precautions when operating over obstacles:

• Always check for obstacles before operating in a new area.

• Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

• Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

• Move the gear selector to Low Gear, if needed.

• Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

• Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

Whenever traveling uphill, follow these precautions:

• Avoid excessively steep hills.

• ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

• Always travel straight uphill.

• Keep both feet on the floor.

• Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

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

• 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.

When driving downhill, follow these precautions:

• Avoid excessively steep hills.

• ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

• 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.

• Slow down.

• Apply the brakes slightly to aid in slowing.

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:

• Slow down.

• Exercise extreme caution.

• Avoid crossing the side of a steep hill.

• ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

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

Follow these procedures when operating through water:

1. Determine water depths and current before entering water.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. Avoid operating through deep or fast-flowing water.

   WARNING

   The large tires on your vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your vehicle

5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

   NOTE

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

Follow these precautions when operating in reverse:

• Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing.

• Always avoid backing downhill.

• Back slowly.

• Apply the brakes lightly for stopping.

• Avoid turning at sharp angles.

• Never open the throttle suddenly.

To park the vehicle, do the following:

1. Apply the brakes. Stop the vehicle on a level surface.

2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

3. Place the transmission in PARK.

4. Engage the park brake.

5. Turn the engine off.

6. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle

7. Remove the ignition key to prevent unauthorized use.

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. Engage the parking brake (if equipped).

4. Turn the engine off.

5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. Block the rear wheels on the downhill side.

POLARIS recommends the use of POLARIS Diesel Oil 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

SAE 5W-40
	SAE 15W-40
-25 f (-31 c)	+5 f (-15 c)	+80 f (+27 c)	+104 f (+40 c)

To check the oil, do the following:

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down before removing the dipstick.

3. Raise the cargo box. Remove the dipstick 1 and wipe it dry with a clean cloth.

4. Reinstall the dipstick and push it into place.

   NOTE

   Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

5. Remove the dipstick and check the oil level.

6. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

   
   NOTE

   A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the upper mark, change the oil immediately.

7. With the cargo box raised, add engine oil through the oil fill cap 2 located on top of the valve cover, under the cargo box.

   

8. When finished, reinstall the dipstick. Lower the cargo box and secure in position.

   TIP

   Be sure to check around and under the engine for signs of oil leakage.

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

The engine oil fill cap is located on top of the valve cover. Access the oil fill cap by tilting the rear cargo box.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

   CAUTION

   Use caution when performing this procedure. Do not allow hot engine oil to come into contact with skin, as serious burns may result.

4. Place a drain pan under the engine crankcase and remove the drain plug 1. Allow the oil to drain completely.

   

5. Remove all cargo from the cargo box.

   CAUTION

   Always remove all cargo from the cargo box before lifting the box to access the engine.

6. Pull up on the cargo box release lever to tilt the box.

7. Remove the mud guard by unscrewing its four bolts 2.

   

8. Using an oil filter wrench, turn the oil filter 3 counter-clockwise to remove it.

   

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

10. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

11. Install the new filter and turn by hand until the filter O-ring contacts the sealing surface, then turn an additional 3/4 turn

12. Replace the sealing washer on drain plug.

    NOTICE

    The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.

13. Reinstall the engine crankcase drain plug. Torque the drain plug to 16 Nm (12 ft-lbs).

14. Remove oil fill cap and add 3.7 L (3.9 quarts) of recommended oil. Reinstall the fill cap.

15. Verify the transmission is still in PARK.

16. Start the engine and allow it to idle for 30 seconds.

17. Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

18. Remove the dipstick and wipe it dry with a clean cloth.

19. Reinstall the dipstick and push it into place.

    NOTICE

    Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent.

20. Remove the dipstick and check the oil level.

21. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

    
    NOTICE

    Add oil slowly, to make sure oil does not get into the breather or intake.

22. When finished, reinstall the oil fill cap and oil dipstick.

23. Dispose of used oil and filter properly.

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water.

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequentially, engine damage.

1. Lift the hood.

   CAUTION

   Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

2. Slowly remove the radiator cap 1.

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. Your POLARIS dealer can provide the correct replacement part.

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottle 2.

3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid. Remove the cap and use a funnel to add coolant through the filler opening. Reinstall the cap.

If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt.

To remove the belt, do the following:

1. Remove the mud guard by unscrewing its two bolts 2.

2. Remove the nine fasteners 1 that retain the outer clutch cover.

   

   
   
   NOTE

   Removal of left rear wheel or left rear shock is NOT necessary for belt replacement.

3. Pull the clutch cover forward and slide towards the front of the vehicle as shown above.

4. Rotate the clutch cover back and lift up and over the control arm mounting 2.

   NOTE

   Use care when lifting clutch cover upwards. Do not damage cover, intake boot, or electrical harness.

   

   

5. Pull clutch cover out towards the rear of the vehicle as shown above.

6. Mark the drive belt direction of rotation so that it can be installed in the same direction.

7. Insert clutch spreader tool 3 into threaded hole on driven clutch as shown and turn clockwise to spread clutch.

   

   NOTE

   Clutch spreader tool part number 2875911 is found in vehicle tool kit.

8. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

To inspect the drive belt, do the following:

1. Inspect belt for hour-glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.

2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation.

1. With the clutch spreader tool 1 installed, loop the belt over the drive clutch and over the driven clutch.

   

   

2. Rotate the driven clutch and walk the belt into the clutch.

3. Remove the clutch spreader tool from driven clutch.

4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch.

5. Install the clutch cover into wheel well as shown above.

6. Rotate clutch cover over A-Arm 2 as shown below. Use care not to damage intake boots or electrical harness.

7. Pull clutch cover backwards and align with bolt holes on inner clutch cover as shown below.

   

   
8. Install and torque the outer clutch cover bolts to specification.

   

   
   
   TORQUE

   PVT Outer Cover Fasteners

   35 in-lbs (4 Nm)

9. Reinstall the mud guard.

If the throttle pedal has excessive play due to cable stretch or maladjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.

Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart. Adjust the freeplay if necessary.

1. Apply the brakes. Engage the park brake. Shift the transmission to neutral.

2. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1.6-3.2 mm (1/16 to 1/8 inches).

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment.

Always replace tires when tread depth is worn to 1/8 in (3 mm) or less.

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.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK and apply the park brake. 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.

1. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing 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. Your dealer can assist.

2. Attach the wheel nuts and washers and finger-tighten.

3. Carefully lower the vehicle to the ground.

4. Torque the wheel nuts to specification.

• 1 Indicator Bulb

• 2 Position Bulb

• 3 High/Low Bulb

Position Bulb and Indicator Bulb Replacement

1. Remove the hood from the front cab.

2. Locate the bulb on the back side of the headlight housing.

3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring.

4. Turn the bulb counterclockwise and remove it from the headlight housing.

5. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place.

   NOTE

   Make sure the tab on the bulb locates properly in the housing.

6. Install the harness onto the new headlight bulb and install the hood.

High/Low Bulb Replacement

1. Remove the hood from the front cab.

2. Locate the High/Low bulb on the back side of the headlight housing.

3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring.

4. Remove the rubber bulb cover, release the bulb protection spring 1 and remove the bulb from the headlight housing.

   

5. Install the new bulb into the housing.

   NOTE

   Make sure the tab on the bulb locates properly in the housing.

6. Make sure the bulb catches on the protection spring. Reinstall the rubber bulb cover.

7. Install the harness onto the new High/Low bulb and install the hood.

To adjust the headlight beam, do the following:

1. Place the vehicle on a level surface with the headlight approximately 25 ft (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Apply the brakes. Start the engine. Turn on the headlights.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8 in (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat while performing this step.

5. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

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

To check the brake lights, do the following:

1. Turn the key 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 bulb.

• A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper 1 and lower level 2 marks.

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

To remove the battery, do the following:

1. Remove the storage bin under the passenger seat to access the battery.

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

3. Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last.

4. Remove the battery hold-down strap.

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

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 instructions in the Battery Charging (Conventional Battery) section before installing the battery.

An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. On conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

   WARNING

   Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

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

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Install the battery hold-down strap and tighten the screws.

8. Verify that cables are properly routed.

9. Reinstall the seat.

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.

1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. Make sure the positive terminal is toward the front of the vehicle.

The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

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

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

• Wheels and tires

• Suspension components

• Brake components

• Seat components

• Clutches and components

• Steering components

• Batteries

• Light bulbs/Sealed beam lamps

• Filters

• Lubricants

• Bushings

• Finished and unfinished surfaces

• Carburetor/Throttle body components

• Engine components

• Drive belts

• Hydraulic components and fluids

• Circuit breakers/Fuses

• Electronic components

• Spark plugs

• Sealants

• Coolants

• Bearings

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer, or other qualified person. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer, or other qualified person, that sells the same line as your product.

If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer, or other qualified person. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your product.

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.