Polaris 2009 99 Ranger User Manual

1UNDERSTANDING WARNINGSSAFETY ALERTThe following precautionary signal words are used throughout this manual to con-vey the following messages:This is

91SPECIFICATIONSDDriving System Type PVTDRShift Type Single Lever/Center ConsoleRIVGear Reduction - Low 24.16:1VEGear Reduction - Reverse 18.67:1ETGea

92WARRANTY

93WARRANTYLIMITED WARRANTYPolaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota55441-5078, gives a SIX MONTH LIMITED WARRANTY on all

94WARRANTYWARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORTOR OTHERWISE. Some states do not permit the exclusion or limitation of inciden-tal

INDEX95Air Cleaner 70. . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 31. . . . . . . . . . . . . . . . . . . Backing Up 54. . . . . . . .

2SAFETY WARNING AND OPERATION DECALSVEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATHThis cab frame is not designed or intended to provide rollover

3SAFETY WARNING AND OPERATION DECALSRecoil handle must be firmly seated toprevent water entry. Drain starter motorif water enters. See owner’s manua

4SAFETY WARNING AND OPERATION DECALSText found below7077683OPERATOR/LOAD DISTRIBUTION WARNINGSVIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE L

5SAFETY WARNING AND OPERATION DECALSTHE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING INA LOADED CONDITION on rough or hilly terrain. When

6SAFETY WARNING AND OPERATION DECALSText found below7077680READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFOREOPERATION. SEVERE INJURY OR DEATH

7SAFETY WARNING AND OPERATION DECALS OPERATION ON HILLS IS DANGEROUS, especially when loaded. Thisvehicle is designed for utility usage on moderate

8LABEL LOCATION2465131. Warning (General)2. Warning (Vehicle roll-over)3. Warning (Load Distribution)4. Warning (Cargo Bed)5. Tire Pressure6. Towing I

9DAILY PRE-RIDE INSPECTIONInspect your vehicle each time before riding to ensure it is in proper workingorder. If proper inspection is not done, seve

10OPERATION WARNINGSWARNINGWARNINGPOTENTIAL HAZARDOperating this vehicle without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly

11OPERATION WARNINGSWARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfaces.WHAT CAN HAPPENThis vehicle’s tires are designed for off-road use

12OPERATION WARNINGSWARNINGWARNINGPOTENTIAL HAZARDOperating this vehicle after consuming alcohol or drugs.WHAT CAN HAPPENCould seriously affect your j

13OPERATION WARNINGSWARNINGPOTENTIAL HAZARDFailure to inspect the vehicle before operating.Failure to properly maintain the vehicle.WHAT CAN HAPPENInc

14OPERATION WARNINGSWARNINGPOTENTIAL HAZARDFailure to use extra care when operating on excessively rough, slip-pery or loose terrain.WHAT CAN HAPPENCo

15OPERATION WARNINGSWARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AV

16OPERATION WARNINGSWARNINGWARNINGWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision

17OPERATION WARNINGSWARNINGPOTENTIAL HAZARDOperating this vehicle through deep or fast flowing water.WHAT CAN HAPPENTires may float, causing loss of t

18OPERATION WARNINGSWARNINGPOTENTIAL HAZARDOperating this vehicle with improper modifications.WHAT CAN HAPPENImproper installation of accessories or m

19OPERATION WARNINGSPOTENTIAL HAZARDOverloading this vehicle or carrying or towing cargo improperly.WHAT CAN HAPPENCould cause changes in vehicle hand

20VEHICLE IDENTIFICATION NUMBERSImportant: Record these numbers from your vehicle in the spaces provided.1. Frame VIN:3. Engine Serial Number (Righ

WARNINGThe engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.

21CONTROL PARTS AND FUNCTIONSFuel GaugeThe fuel gauge on the instrument panel shows the amount of fuel in the fuel tank.When the red indicator needle

22CONTROL PARTS AND FUNCTIONSParking Brake LeverThe parking brake lever is located at the right side of the driver’s seat. Pull the leverup and to th

23CONTROL PARTS AND FUNCTIONSSeat BeltsThe vehicle is equipped with lap-style seat belts for the operator and passenger.WARNINGSeat belts reduce injur

24CONTROL PARTS AND FUNCTIONSEngine Fueland Oil SystemThe fuel tank filler cap (1) is lo-cated on the left side by the driv-ers seat. Use either lead

25CONTROL PARTS AND FUNCTIONSWARNINGGasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever ha

26CONTROL PARTS AND FUNCTIONS Never use gasohol with an octane rating lower than the minimum octane rat-ing specified for this product. Never use gaso

27CONTROL AND PARTS FUNCTIONSVEHICLE NOMENCLATURE - Left View1. Cab Frame2. Cab Frame Hand Hold3. Dashboard4. Steering Wheel5. Gear Shift Lever6. Seat

28CONTROL AND PARTS FUNCTIONSVEHICLE NOMENCLATURE - Front View14161513121212. Headlights13. Air Box (under hood)14. Battery (under hood)15. Radiator (

29CONTROL AND PARTS FUNCTIONSVEHICLE NOMENCLATURE - Rear View17182120 191717. Tail Gate Latches (Top and Bottom)18. Tail Gate19. Muffler (Spark Arrest

30CONTROL AND PARTS FUNCTIONSVEHICLE NOMENCLATURE - Instrument Panel1228111375694101. Choke Knob2. Ignition Switch3. Hour Meter4. Passenger Warning De

FOREWORDCongratulations and thank you from Polaris Industries Inc. for purchasing one ofour products. Built with American engineering and manufacturi

31CONTROL AND PARTS FUNCTIONSDemand 6 DriveExclusive Demand 6 Drive System (All Wheel Drive)This Polaris AWD is equipped with a unique, Polaris exclus

32CONTROL AND PARTS FUNCTIONSTransmission Gear Selector OperationThe transmission gear selector is located tothe right of the vehicle driver’s seat. T

33CONTROL AND PARTS FUNCTIONSDisengaging Wheel HubsWhen backing uphill while in Demand 6 Drive and then going forward downhill, oneor both hubs may re

34CONTROL AND PARTS FUNCTIONSEngine Cooling SystemCoolant LevelThe recovery bottle (1), locatedon the left side of the machinemust be maintained betwe

35CONTROL AND PARTS FUNCTIONSEngine Cooling System Radiator Coolant Level InspectionNOTE: This procedure is only required if the cooling system has

36CONTROL AND PARTS FUNCTIONSEngine Cooling SystemTo insure that the coolant maintains its ability to protect the engine, it is recom-mended that the

37CONTROL AND PARTS FUNCTIONS4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulatedfor

38CONTROL AND PARTS FUNCTIONSOil and Filter ChangeThe recommended oil change interval is 100 hours, 1000 miles, or every sixmonths, whichever comes fi

39CONTROL AND PARTS FUNCTIONSOil and Filter Change (Cont.)14. Reinstall drain plug.15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premi

40STARTING THE ENGINEStopping the Engine1. Release the throttle pedal completely.2. Put the gear shift lever into (N) Neutral.3. Apply the parking bra

THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.This vehicle handles differently from other vehicles including motor-cycles and cars. A col

41STARTING THE ENGINE7. If engine does not start, release ignition switch and wait five seconds; then turnthe ignition switch to start for another fi

42STARTING THE ENGINEProcedure for Starting a Warm EngineWarm engines do not normally require the use of the choke since the spark plugcan easily beco

43STARTING THE ENGINERecoil StarterRecoil StarterIf the battery is weak and cannot start the engine, use of the recoil starter locatedon the right sid

44VEHICLE BREAK-IN PERIODThe break in period for your new Polaris RANGER is defined as the first twentyhours of operation, or the time it takes to use

45CARRYING LOADSThe RANGER has been designed to carry or tow a certain amount of load. Alwaysread and understand the load distribution warnings liste

46OPERATING SAFETYLoad Distribution1. Always load the cargo box placing the load as far forward as possible.2. Always operate the vehicle with extreme

47OPERATING SAFETY1. Sit in the driver’s seat with the seatbelt fastened.2. After starting the engine and allowing it to warm up, shift the transmissi

48OPERATING SAFETYRiding On Slippery SurfacesWhenever driving on slippery surfaces such as wet trails or loosegravel, or during cold freezing weather,

49OPERATING SAFETYOperating on HillsWARNINGImproperly crossing hills or turning on hills can be dangerous!Loss of vehicle control or overturning of th

50OPERATING SAFETYBraking and handling are greatly affected whenever operating in hilly ter-rain.Loss of vehicle control or overturning of the vehicle

 Always follow proper procedures for going down hills and for braking on hills asdescribed in this manual. Check the terrain carefully before you st

51OPERATING SAFETYWARNINGGoing down a hill improperly could cause loss of control or cause the ve-hicle to overturn.Always check the terrain carefully

52OPERATING SAFETYCrossing StreamsYour Polaris RANGER can operate through water up to depths reaching the floor-boards. Before fording streams always

53OPERATING SAFETYTrail ObstaclesKeep Alert!Look ahead and learn to read the trail as you ride. Stay on the right side of the trail,if possible, and

54OPERATING SAFETYBacking Up1. When backing up, always avoid backing downhill.2. Back slowly.3. When in reverse, apply the brakes lightly for stopping

55OPERATING SAFETYDumping the Cargo Box1. Select a level site to dump thecargo box. Do not attempt todump or unload the vehiclewhile parked on an inc

56NOISE EMISSION CONTROL SYSTEM REGULATIONTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing

57BATTERYBattery CAUTIONWhenever removing the battery, discon-nect the negative (black) cable first. Whenreinstalling the battery, connect the nega-t

58BATTERYBattery Removal1. Disconnect hold down strapsholding the battery (1) in positionand remove battery retainer.2. Remove the battery vent tubefr

59MAINTENANCEPeriodic Maintenance ScheduleCareful periodic maintenance will help keep your vehicle in the safest, most reliablecondition. Inspection,

60MAINTENANCEPeriodic Maintenance Schedule (Cont.)Item Hours orOdometerFrequency RemarksFuel System 100 hours 12 months Check for leaks at fuel cap,

indicates a potential hazard whichcould result in serious injury or death.WARNINGAdditional Important Information...Due to our concern for the safety

61MAINTENANCEPeriodic Maintenance Schedule (Cont.)Item Hours orOdometerFrequency RemarksHeadlamp Inspection Daily Daily Check operation daily; apply P

62MAINTENANCELubrication RecommendationsItem Lube Rec. Method Frequency*1.Engine Oil Polaris Pre-mium 4 Syn-thetic 0W40Add to proper level on dipstic

63MAINTENANCELubrication RecommendationsOperatingRangeFull3. Transmission6. Front Prop Shaft(U-Joint)9. Axle CardanFront Drive(AWD Models)5. Center H

64MAINTENANCELubrication Recommendations11. Front A ArmPivot ShaftGrease**∆ Locate fitting on pivot shaft andgrease with grease gun.Every 3months or 5

65MAINTENANCELubrication Recommendations13. Upper ControlArm16.17.

66MAINTENANCEWARNINGVehicle operation with insufficient, deteriorated, or contaminated engineoil will cause accelerated wear and may result in engine

67MAINTENANCETransmission Oil ChangingProcedure1. Locate and remove fill plug/dipstick.2. Remove transmission drainplug located on the bottomright han

68MAINTENANCEFront Gearcase LubricationFill plug/DipstickFront Gearcase LubricationThe front gearcase fill plug is located on the right side of the fr

69MAINTENANCEThe following items should be checked occasionally for tightness; or if they havebeen loosened for maintenance service.Axle and Wheel Nut

70MAINTENANCERear Spring AdjustmentThe rear shock absorber springs areadjusted by rotating the adjuster inthe direction required to increase ordecreas

The Polaris PreferredRegistered Owners (PRO) FamilyYour Owners ProgramAs the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem-

71MAINTENANCECAUTION: Operation of your vehicle without a breather filter can cause enginedamage.Breather Filter and HosesDo not perform this operatio

72MAINTENANCECoolant Level InspectionNOTE: Check the coolant levelwhen the engine is cold (room oratmospheric temperature).1. Situate the vehicle on

73MAINTENANCESpark Plugs Proper electrode gap is .028″/.7mm. Spark plug torque is 17 ft. lbs. (2.3 kg/m). Use NGK BKR5ES spark plugs. Proper e

74MAINTENANCESpark ArrestorThe exhaust pipe must be period-ically purged of accumulated car-bon as follows:1. Remove the clean out plugslocated on the

75MAINTENANCETool KitTo help you perform routine maintenance, a tool kit is provided in the storagecompartment under the seat. Items included in the

76MAINTENANCEThrottle PedalIf the throttle pedal (1) has exces-sive play due to cable stretch orcable misadjustment, it will cause adelay in throttle

77MAINTENANCECarburetorThe idle speed adjustment should be performed in accordance with the PeriodicMaintenance Chart or whenever the idle speed is ch

78MAINTENANCEFront and Rear BrakesThe front and brakes are hydraulicdisc type brakes activated by thebrake pedal.The following checks are recom-mended

79MAINTENANCERear BrakeThe rear brake is a hydraulic disctype brake which is activated by thesame pedal which activates the frontbrake system. The re

80MAINTENANCEParking Brake LeverThe parking brake helps hold thevehicle from rolling while parked.Make sure the parking brake leveris functioning prop

CONTENTSUNDERSTANDING WARNINGS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY WARNING AND OPERATION DECALS 2-7. . . . . . . . . . . .

81MAINTENANCEWheel Removal Procedure1. Stop the engine, place the transmission in gear and lock the parking brake.2. Loosen the wheel nuts slightly.3.

82MAINTENANCETire InspectionCAUTION: Maintain proper tire pressure according to charts below. Improper tireinflation may affect vehicle maneuverabil

83MAINTENANCESeat BeltsMake certain each seat belt functions properly before each ride. Push the latchplate into the buckle until it clicks. The lat

84MAINTENANCEHeadlight BeamThe headlight beam can be adjusted up and down.1. Place the vehicle on a level surface with the headlight approximately 25’

85MAINTENANCEWARNINGGasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

86MAINTENANCECleaning Your RANGERKeeping your vehicle clean will not only improve its appearance but it can also ex-tend the life of various component

87MAINTENANCEStorageIf your vehicle is to be placed in extendedor off season storage, the following stepsshould be taken to preserve its condition.1.

88MAINTENANCEWARNINGDo not run the engine in a closed area. Exhaust gases contain carbonmonoxide; a colorless, odorless, poisonous gas. Breathing ex

89TROUBLESHOOTINGProceduresThe following information is provided to help you identify probable causes for ques-tions you may have about the operation

90SPECIFICATIONSGross Vehicle Weight 3020 lbs.Fuel Capacity 9.5 GallonsCTowing Capacity 1500 lbs.CAMaximum Cargo Box Load 1000 lbs.APAOverall Length 1