Polaris 4X4 700 EFI Owner's Manual
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Polaris 4X4 700 EFI Owner's Manual

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  • Page 3 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Specifications ......108 Polaris Products..... . . 112 Troubleshooting .

  • Page 7: Vehicle Identification Numbers

    Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.

  • Page 8: Safety

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

  • Page 9: Safety Decals And Locations

    Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
  • Page 10 The park/emergency brake 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 MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.

  • Page 11: Operator Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.
  • Page 12 Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.
  • Page 13 Operator Safety Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow the operating proce- dures described. •...
  • Page 14 Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities.
  • Page 15 See page 21 for fuel safety warnings. • Always remove the ignition key when the vehicle is not in use to pre- vent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800- 342-3764.

  • Page 16: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 17 Operator Safety POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power.
  • Page 18 Operator Safety POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.
  • Page 19 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention.
  • Page 20 Operator Safety POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice.
  • Page 21 SAFETY Operator Safety POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition.
  • Page 22 Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are...
  • Page 23 Operator Safety Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. 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.
  • Page 24 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 or near the refueling area or where gasoline is stored.

  • Page 25: Features And Controls

    FEATURES AND CONTROLS Component Locations 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 108. Cab Frame (if Equipped) Steering Wheel...

  • Page 26: Component Locations

    FEATURES AND CONTROLS Component Locations Headlights Radiator (if equipped) Hood Hold-Down Strap Front Bumper/Brush Guard...
  • Page 27 FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Taillights Tailgate Air Box CV Boot/Rear Caliper Receiver Hitch Muffler (Spark Arrestor) Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 50-53.

  • Page 28: Instrument Cluster

    FEATURES AND CONTROLS Component Locations Instrument Cluster Your RANGER is equipped with an instrument cluster that senses vehi- cle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. Refer to page 34 for the location of the instrument cluster.

  • Page 29: Rider Information Center

    If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear shifter position.

  • Page 30: Clock Mode

    Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 34. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
  • Page 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).

  • Page 33: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Center, depend- ing on your preference.
  • Page 34 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 32 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground Engine Temp Sensor Circuit: Open or Short to Battery...

  • Page 36: Seat Removal

    Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

  • Page 37: Auxiliary Outlet

    FEATURES AND CONTROLS Console AWD/Differential Switch Instrument Light (if equipped) Gauge Switch Holder Holder Ignition Accessory Storage Switch Storage Outlet Compartment Storage (with lid) Mode Tray Button Auxiliary Outlet The 12-volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights.

  • Page 38: Gear Selector

    Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for the RANGER. High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

  • Page 39: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Depress the brake Brake pedal to slow or stop Pedal the vehicle. Apply the brakes while starting the engine. Throttle Pedal Park Brake Push the pedal down Release to increase engine speed. Spring pressure Park Brake Throttle returns the pedal to the Pedal...

  • Page 40: Ignition Switch

    Switches Ignition Switch Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. The ignition switch is a three-position, key-operated switch.

  • Page 41: Operation

    Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.
  • Page 42 Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced OPERATION Page...

  • Page 43: Starting The Engine

    Starting the Engine 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. 1. Sit in the driver's seat and fasten the seat belt. 2.

  • Page 44: Stopping The Engine

    Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Engage the park brake. A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. Braking 1.

  • Page 45: Driving Safely

    Driving Safely Driving Procedure 1. Sit in the driver's seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 46: Driving On Slippery Surfaces

    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 con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2.

  • Page 47: Driving Uphill

    Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill.

  • Page 48: Driving Downhill

    Driving Safely Driving on a Sidehill (Sidehilling) 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 (15°...

  • Page 49: Driving Through Water

    The large tires on your RANGER 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 RANGER. Your Polaris RANGER can operate through water up to a maximum...

  • Page 50: Driving Over Obstacles

    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. Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle.

  • Page 51: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6.

  • Page 52: Parking On An Incline

    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. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. A rolling vehicle can cause property damage and serious injury.

  • Page 53: Hauling Cargo

    OPERATION Driving Safely Hauling Cargo 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: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 54 Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model RANGER 4X4 EFI RANGER 6X6 EFI Driving with passengers in the cargo box can result...

  • Page 55: Dumping The Cargo Box

    OPERATION Driving Safely Dumping the Cargo Box 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 creating hazardous driving conditions.

  • Page 56: Towing Loads

    Driving Safely Towing Loads 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 bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing.

  • Page 57: Parking The Vehicle

    OPERATION Driving Safely Parking the Vehicle A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. Turn the engine off. 3. Engage the park brake. 4.

  • Page 58: Locking The Differential

    Differential Lock (4X4 Models) Locking the Differential The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. Locking the differential in slippery or low traction conditions helps improve traction.

  • Page 59: Disengaging Awd

    OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.

  • Page 60: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 61: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 126.

  • Page 62: Periodic Maintenance Chart

    Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
  • Page 63 (if equipped) Transmission oil Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Miles...
  • Page 64 Engine oil change Oil filter change Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar...
  • Page 65 Auxiliary brake (if equipped) Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California). Have an authorized Polaris dealer perform these services Maintenance Interval (whichever comes first) Hours Calendar Miles...

  • Page 66: Lubrication Recommendations

    Rear Gearcase Oil Prop Shaft U-joints Front Prop Shaft Yoke Ball Joint Swing Arm Bushings Lube Polaris Premium 4 Synthetic 0W40 DOT 3 or DOT 4 Premium AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Premium ATV Angle Drive...
  • Page 67 Lubrication Recommendations Swing Arm Bushings Prop Shaft U-Joints Ball Joint...

  • Page 68: Engine Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W- 40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient tem- perature operation.

  • Page 69: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine. 1.

  • Page 70: Oil And Filter Change

    Engine Oil Oil and Filter Change Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always change the oil filter whenever changing oil.

  • Page 71: Gearcase Specification Chart

    MAINTENANCE Engine Oil Oil and Filter Change 1. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 2. Shift the transmission to neutral. 3. Engage the park brake. 4. Apply the brakes. Start the engine. Allow it to idle for one to two minutes.
  • Page 72 Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The fill plug is located at the rear of the vehicle. Oil Check 1.
  • Page 73 Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug.
  • Page 74 Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The front gearcase fill plug is located on the right side of the front gear- case.
  • Page 75 Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The middle gearcase fill plug is located on the side of the gearcase. Oil Check 1.

  • Page 76: Rear Gearcase

    Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The rear gearcase fill plug is on the driver's side of the rear gearcase.
  • Page 77 MAINTENANCE Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. 3. Drain the oil. Dispose of used oil properly. 4. Clean the drain plug. Reinstall the drain plug. Torque to specifica- tion.

  • Page 78: Spark Plugs

    Spark Plugs Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 108. Spark Plug Gap/Torque Model Electrode Gap RANGER .035" (.9 mm) 4X4 EFI RANGER .035" (.9 mm) 6X6 EFI Spark plug condition is indicative of engine operation.

  • Page 79: Spark Plug Condition

    MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

  • Page 80: Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 112 for the part numbers of Polaris prod- ucts. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

  • Page 81: Coolant Level

    Reinstall the cap. NOTE: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer. CAUTION Overflow Bottle...

  • Page 82: Radiator Coolant Level

    Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.
  • Page 83 Polaris Variable Transmission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

  • Page 84: Pvt System

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 85: Pvt Drying

    PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Loosen the bottom screws that secure the clutch cover. 2. Allow the water to drain. 3.

  • Page 86: Filter Systems

    Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter.

  • Page 87: Spark Arrestor

    Spark Arrestor 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 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 88: Throttle System

    Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.

  • Page 89: Throttle Freeplay Adjustment

    MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster.

  • Page 90: Brake Fluid

    Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36. Brake Fluid Inspect the brake system rou- tinely. Inspect the level of the brake fluid before each opera- tion. Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if...

  • Page 91: Brake Inspection

    MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear.

  • Page 92: Steering Wheel Inspection

    4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an autho- rized Polaris dealer. Suspension Adjustment (4X4) The 4X4 rear suspension may be adjusted to provide a stiffer suspension if necessary.
  • Page 93 If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driv- ing.

  • Page 94: Tire Tread Depth

    Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.

  • Page 95: Wheel Removal

    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. Engage the park brake.

  • Page 96: Headlight Lamp Replacement

    Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 97: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 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.

  • Page 98: Vehicle Immersion

    Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below.

  • Page 99: Conventional Battery

    MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion.

  • Page 100: Battery Removal

    Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 101: Battery Installation

    MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 100 before installing the battery.

  • Page 102: Battery Storage

    See page 100. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 103 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 97. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 104 Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action specified on top of battery) None, check at 3...

  • Page 105: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 106: Washing The Vehicle

    • Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 107 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 108: Fluid Levels

    Make any necessary repairs and clean the vehicle as recommended. See page 102. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...

  • Page 109: Battery Maintenance

    6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Battery Maintenance See pages 99-101 for storage and charging procedures.

  • Page 110: Removal From Storage

    39. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.

  • Page 111: Specifications

    SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min.
  • Page 112 Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for clutching specifications. RANGER 4X4 EFI Pressurized Wet Sump 0W/40 PVT, 4-wheel independent shaft, lockable differ- ential Single Lever (H/L/N/R) 8.71:1 5.94:1...
  • Page 113 Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Engine Displacement Bore x Stroke Alternator Output...
  • Page 114 Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for clutching specifications. RANGER 6X6 EFI Pressurized Wet Sump 0W/40 Single Lever, Console (H/L/N/R) 8.71:1 5.9:1 3.14:1 3.83:1 3.70:1...

  • Page 115: Polaris Products

    2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2870990 DOT 3 Brake Fluid 2872893 Engine Degreaser (12 oz.) 2871956 Loctite 2871076 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 116: Troubleshooting

    Dry out the PVT. See page 82. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
  • Page 117 Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs and replace if necessary Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark plugs...
  • Page 118 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...
  • Page 119 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...

  • Page 120: Warranty

    ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 121 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer.
  • Page 122 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 123 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
  • Page 124 Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Most Clean Least Clean...
  • Page 125 Polaris Warranty Department at 1-763-417-8650. Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with...
  • Page 126 (iii) Filter lock assy (gaseous fuel, if applicable) If an authorized dealer determines that other LSI engine components have been dam- aged due to the failure of a warranted emission-related part during the warranty period, POLARIS will repair and/or replace the necessary components. WARRANTY...

  • Page 127: Maintenance Schedule

    When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
  • Page 128 Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the per- formance of any warranty maintenance or repairs of emission-related parts. These replacement parts will be provided at no charge if the part is still under warranty.

  • Page 129: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 130 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 131: Index

    INDEX Accessory Outlet ....34 Adding Coolant ....77 Adjustment, Headlight Beam..94 Adjustment, Park Brake.

  • Page 132: Emission Control

    Driving on Slippery Surfaces ..43 Driving Over Obstacles ..47 Driving Procedure....42 Driving Safely.

  • Page 133: Park Brake

    Plugs, Spark ....75-76 Polaris Products ....112 Polishing the Vehicle... . 103 Pre-Ride Inspection .

  • Page 134: Spark Plug

    Receiver Hitch ....24 Release, Park Brake ... . . 36 Removal, Battery ....97 Removal, Seat .

This manual is also suitable for:

6x6 700 efiRanger 4x4 700 efi 2007Ranger 6x6 700 efi 2007

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