2005 Polaris Ranger 6x6 Owners Manual

2005 Polaris Ranger 6x6 Manual

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2005 Polaris Ranger 6x6 manual content summary:

  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 1
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 2
    WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 3
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 4
    or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. RANGER 4X4/6X6/TM Owner's Manual P/N 9919534 2
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 5
    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
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 6
    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. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 7
    TABLE OF CONTENTS WELCOME ...3 VEHICLE IDENTIFICATION NUMBERS ...4 SAFETY ...7 FEATURES AND CONTROLS ...25 OPERATION ...34 EMISSION CONTROL SYSTEMS ...52 MAINTENANCE AND LUBRICATION ...54 POLARIS PRODUCTS ...99 SPECIFICATIONS ...100 TROUBLESHOOTING ...106 WARRANTY ...109 INDEX ...117 5
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 8
    6
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 9
    routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating the vehicle. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 10
    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The damage to the vehicle. NOTE: A note will alert you to important information or instructions. 8
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 11
    Safety WARNING 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. S Read this manual and all labels carefully. Follow the operating procedures described. S Never allow anyone without a valid
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 12
    of skidding or sliding out of control. S 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
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 13
    exceed the stated load capacity for this vehicle. Cargo should be properly distributed 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. S Always wear the seat belts when operating this vehicle
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 14
    SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 15
    begin rolling backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake. In the event of an accident, have a qualified service dealer check the complete vehicle for possible damage, including (but not limited to) brakes, throttle and steering. 13
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 16
    do not make sudden turns or stops. WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle. 14
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 17
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it's illegal
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 18
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 19
    use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control, vehicle
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 20
    HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner's Manual for this vehicle. See page 101. Always maintain proper tire pressure as described on the decal and in the Owner
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 21
    or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. CAUTION Always keep combustible
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 22
    of the decals on the RANGER carefully. If any of the decals depicted in this manual differ from the decals on your RANGER, always read and follow the instructions of the decals on the RANGER. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 23
    SAFETY Safety Decals and Locations 4 1 3 2 WARNING WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Remove flammable containers from box before refueling. WARNING Maximum Box Load is ___ lbs. Location 4 (inside front of box)
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 24
    USE ON PUBLIC ROADS. 5 CE VÉHICULE USAGE GENERAL VEHICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS. and adjustments are required depending on temperature and altitude. See your Owner's Manual. Factory setting: 40_ to 80_ F. at 0-3000 feet (5_ to
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 25
    lever will supply increased braking, but should be used as an emergency or parking brake only. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 26
    SAFETY Fuel Safety WARNING Gasoline is highly flammable and is 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. Do not smoke or allow open flames or sparks in
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 27
    FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 100. Component Locations 1 3 4 2 5 6 9 7 8 1. 2. 3. 4. 5. 6. 7. 8. 9. Cab Frame (if equipped) Hip
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 28
    FEATURES AND CONTROLS Component Locations 10 13 12 11 10. 11. 12. 13. Headlights Radiator (if equipped) Front Bumper/Brush Guard Hood Hold Down Strap 26
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 29
    FEATURES AND CONTROLS Component Locations 16 15 14 14 17 20 18 19 18 14. 15. 16. 17. 18. 19. 20. Taillights Tailgate Tailgate Latch Release Muffler (Spark Arrester) CV Boot/Rear Caliper Air Box Receiver Hitch 27
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 30
    FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display: 6 4 1. High Gear 2. Low Gear (if equipped) 3. Neutral Gear 4. Reverse Gear 5. High Temperature 6. Brakes 2 Trailer Hitch Bracket 5 3 1 This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 31
    twisted. 2. Push the latch plate into the buckle until it clicks. 3. Release the strap, it will self tighten. NOTE: The center belt must be tightened manually by pulling on the strap. To unfasten, press the square red button in the buckle's center. 29
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 32
    FEATURES AND CONTROLS Console 1 2 3 4 5 6 1 13 12 11 10 9 8 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cup Holder Indicator Lights Shift Lever Light Switch AWD/Differential Switch (if equipped) Hour Meter Glove Box with Lid 12V Accessory Plug Storage Tray Choke Knob Ignition Switch
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 33
    is left unattended. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 34
    three positions: D: AWD E: Differential Lock E F: Off See page 33 for differential switch operating F instructions. Vehicles equipped with AWD can be operated in either 2WD or AWD. Press the AWD switch to possible for the AWD to remain engaged. See page 51 for manual disengagement instructions. 32
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 35
    FEATURES AND CONTROLS Brake Pedal (1) Depress the brake pedal to slow or stop the vehicle. Throttle Pedal (2) Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 36
    OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 37
    OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Pre-Ride Checklist Item Brake system / lever travel Brake fluid Front suspension
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 38
    OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 39
    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake. 3. Sit in the
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 40
    OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: NOTE: Practice starting and stopping (using the brakes) until you're familiar with the controls. When the throttle pedal is released completely and the engine speed drops near an idle,
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 41
    OPERATION Driving Safely Driving Procedures 1. Sit in the driver's seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 42
    OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 43
    death. Avoid climbing steep hills (15_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 44
    OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 45
    to the lever 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 beginning on page 54. Give special attention to engine oil, transmission oil, front and rear gearcases, and
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 46
    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 47
    injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual. Always back slowly. 45
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 48
    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 49
    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Always load the cargo box with the load as far forward as possible
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 50
    OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 51
    OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 52
    OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 53
    a minimum of 10 feet. 3. Stop completely. 4. Shift into forward and drive. If the hubs remain engaged after following these instructions, return the vehicle to your dealer for service. WARNING Operating with only one front hub engaged could result in loss of control, accident, and severe injury or
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 54
    other adjustments should be performed by an authorized Polaris dealer. The RANGER TM emissions label (1) is located on the front of the engine. Remove the service panel (2) to view the label. The label on the RANGER 4X4 and 6X6 (3) is located on the recoil cover. Remove the seat and look through
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 55
    local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 56
    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 57
    MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) J Steering " Front suspension " Rear suspension Remarks - Pre-Ride
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 58
    H 100 H 100 H 6M 12 M 12 M - E " Oil tank vent hose E J Valve clearance E Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 59
    arrestor E Idle speed J Toe adjustment " Auxiliary brake (if J equipped) Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 60
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More often
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 61
    MAINTENANCE AND LUBRICATION Lubrication Recommendations TM 6X6 (2) TM 6X6 (1) 4X4 6X6 6X6 59
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 62
    MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 63
    MAINTENANCE AND LUBRICATION Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check (RANGER 4X4, 6X6) The oil tank is located under the seat. 1.
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 64
    MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER 4X4, 6X6) CAUTION Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin. 1. Run the engine two to three minutes until warm. Stop the engine. 2. Clean the area around the drain plug (B) at the bottom
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 65
    MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER 4X4, 6X6) 14. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 15. Approximately one cup of engine oil will remain in the crankcase. To drain, remove
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 66
    2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 29. Remove the service panel (1) by pulling upward. 4. Remove the dipstick (2) and wipe it dry with a clean cloth. 5. Replace the dipstick and seat it completely. 6. Remove the dipstick
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 67
    MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER TM) 5. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 6. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 68
    MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Main Gearcase (Transmission) (4X4, 6X6) Main Gearcase (Transmission) (TM) Front Gearcase (4X4, 6X6) Middle Gearcase (6X6) Rear Gearcase (4X4) Rear Gearcase (6X6, TM) Lubricant Premium AGL Synthetic Gearcase Lube Premium AGL
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 69
    MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom of the fill plug hole. We recommend the use of Premium AGL
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 70
    the oil level. 3. Add the recommended hub fluid as needed. 4. Reinstall the fill plug. Torque to specification. See page 66. 1 Oil Change 2 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's side. 3. Remove the fill plug. 4. Remove the gearcase drain plug
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 71
    MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase (RANGER 6X6) Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 72
    MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of Polaris ATV Angle
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 73
    MAINTENANCE AND LUBRICATION Cooling System (RANGER 4X4, 6X6) Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 74
    MAINTENANCE AND LUBRICATION Cooling System (RANGER 4X4, 6X6) Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Do not obstruct or deflect air flow through the radiator by installing
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 75
    MAINTENANCE AND LUBRICATION Cooling System (RANGER 4X4, 6X6) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 76
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 77
    maintenance procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Shift the transmission service as soon as possible. 75
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 78
    screw. 8. Reconnect the fuel pump wires. 9. Attempt to start the engine. If necessary, repeat the drying procedure. 10. Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT follow the procedure on
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 79
    the sealing edges of the filter before installing. 5. Inspect the air box for oil or water deposits. If present, drain them into a suitable container. NOTE: Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. 77
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 80
    the clamps. 2 1 CAUTION Operation of the vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service. Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 81
    MAINTENANCE AND LUBRICATION Filter Systems (RANGER TM) Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. 1. Remove the seat to access the air cleaner. 2. Remove the breather hose (1) from the cylinder. 3. Remove the
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 82
    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000q F. Allow components
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 83
    MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge accumulated
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 84
    start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation. Throttle Freeplay
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 85
    MAINTENANCE AND LUBRICATION Throttle System Throttle Cable Adjustment (RANGER TM) If the proper freeplay cannot be obtained with the throttle block adjuster, adjust the cable at the carburetor using the following procedure. 1. Remove the seat and loosen the 1 clamp screw (1) and the throttle cable
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 86
    MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 33. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 87
    MAINTENANCE AND LUBRICATION Brakes Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear. 9.
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 88
    Head/Cylinder Base Fastener Torque Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam (1) either clockwise or
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 89
    MAINTENANCE AND LUBRICATION Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red button
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 90
    . 1/8I (.3 cm) Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Location Front Wheel Nuts Rear Wheel Nuts Front Spindle Nut Center and Rear Hub Retaining Nuts Specification 35 ft. lbs. (47 Nm) 35
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 91
    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. See your Polaris dealer. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 92
    during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement 1. Open the hood. 2. Unplug the headlamp from the wiring harness (1). Be
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 93
    MAINTENANCE AND LUBRICATION Lights Headlight Beam Adjustment 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. Start the engine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 94
    MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2 2. Reach in behind the console 1 panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 95
    MAINTENANCE AND LUBRICATION Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. The best and safest way to clean your vehicle is with a
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 96
    MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Remove the spark plug and pour approximately one ounce of
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 97
    MAINTENANCE AND LUBRICATION Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 98
    MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 99
    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the 1 upper and lower level marks (1). To refill use only distilled water. Tap water
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 100
    MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 101
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (12 oz. Aerosol)
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 102
    SPECIFICATIONS RANGER TM Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 103
    SPECIFICATIONS RANGER TM Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake,
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 104
    SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 105
    SPECIFICATIONS RANGER 4X4 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake,
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 106
    SPECIFICATIONS RANGER 6X6 Gross Vehicle Weight Fuel Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Ground Clearance Dry Weight Cargo Box (L x W x H) Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 107
    SPECIFICATIONS RANGER 6X6 Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Parking Hood
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 108
    TROUBLESHOOTING Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 109
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 110
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 111
    and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 112
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 113
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 114
    maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you retain all receipts covering your LSI engine to a dealer authorized by POLARIS as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 115
    WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the original retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser and
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 116
    such as changing, adding, or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable to follow the maintenance and operating instructions specified in the 2005 and later Owner's Manual including: (a) Improper or inadequate
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 117
    WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) " Engine oil level Remarks - Pre-Ride - E " Air filter, pre-filter Make adjustments as needed. See Pre-Ride Checklist on page 35. Inspect;
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 118
    . These replacement parts will be provided at no charge if the part is still under warranty. How to File a Warranty Claim/Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 119
    INDEX A Age Restrictions ...7 Air Filter ...77, 79 All Wheel Drive (AWD) ...51 Auxiliary Outlet ...28 AWD Switch ...32 E Electromagnetic Interference ...53 EMISSION CONTROL SYSTEMS ...52-53 Engine Idle RPM Adjustment ...83 Engine Oil ...60-65 Equipment Modifications ...12 Exhaust Emission Control
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 120
    88-89 Tool Kit ...92 Torque Specifications ...88 Towing Capacities ...49 Towing Loads ...49 Trailer Hitch Bracket ...28 Transmission ...67 TROUBLESHOOTING ...106-108 R Radiator and Cooling Fan ...Radiator Coolant Level ...Rear Gearcase ...Rear Spring Adjustment ...Removal from Storage ...72 73 70
  • 2005 Polaris Ranger 6x6 | Owners Manual - Page 121
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