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Polaris Ranger 4x4 700 EFI Owner's Manual

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  • Page 3

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

  • Page 4

    WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • 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.

  • Page 5

    POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 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

    TABLE OF CONTENTS Vehicle Identification Numbers... . . 4 Safety ....... . . 5 Features and Controls .

  • Page 7: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 8: Safety

    SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

  • Page 9

    SAFETY Safety Decals and Locations Discretionary Warning Clutch Cover Warning Age 16 Warning 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

    SAFETY Safety Decals and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees 15°.

  • Page 11: Know Your Vehicle

    SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 12

    SAFETY 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 13

    SAFETY Operator 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. • Read this manual and all labels carefully. Follow the operating proce- dures described.

  • Page 14

    SAFETY Operator Safety • Always follow proper procedures for turning as described in this manual. 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.

  • Page 15

    SAFETY Operator Safety • Never modify this vehicle through improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and fol- low the instructions in this manual for hauling cargo or pulling a trailer.

  • Page 16: Equipment Modifications

    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.

  • Page 17

    SAFETY Operator Safety WARNING 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 gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

  • Page 18

    SAFETY Operator Safety WARNING 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 WARNING 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

    SAFETY Operator Safety WARNING 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. WARNING 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 WARNING 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

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN 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 recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious...

  • Page 23

    SAFETY Operator Safety WARNING 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. 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.

  • 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 110. Cab Frame (if Equipped) Hip Bar Cargo Box Console Seat Belt...

  • Page 26: Component Locations

    FEATURES AND CONTROLS Component Locations Tailgate Tailgate Latch Release 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 54-57.

  • Page 27: Mode Button

    FEATURES AND CONTROLS Console Park Brake Mode Instrument Gear Selector Lever Button Gauge (Shifter) Storage Storage 12V Auxiliary Holder Compartment Tray Outlets Auxiliary Outlets The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood.

  • Page 28: Gear Selector

    FEATURES AND CONTROLS 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 29: Ignition Switch

    FEATURES AND CONTROLS Switches AWD/Differential Switch Light Switch Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.

  • Page 30: Light Switch

    FEATURES AND CONTROLS Switches Light Switch The ignition switch key must be in the ON/ RUN position to operate the headlights. Use the light switch to turn the headlights on or off. AWD/Differential Lock Switch The AWD/Differential Switch has three posi- tions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/ Turf Mode).

  • Page 31

    FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, except neutral.

  • Page 32: Seat Belts

    FEATURES AND CONTROLS Seat Belts WARNING Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER. Passengers under five years of age require special restraints, which are not available with this vehicle.

  • Page 33: Storage Box

    FEATURES AND CONTROLS Storage Box Remove the seat to access the under-seat storage box. Seat Removal Pull up on the front of the seat and slide it toward the front of the vehi- cle. 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 34: Brake Pedal

    FEATURES AND CONTROLS Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider pref- erence. Lift and hold the adjustment lever toward you while moving the steer- ing wheel upward or downward. Release the lever when the steering wheel is at the desired position.

  • Page 35: Instrument Cluster

    FEATURES AND CONTROLS 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 24 for the location of the instrument cluster.

  • Page 36

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 2.5 seconds at start-up. NOTE: 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.

  • Page 37

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 24. 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 38: Diagnostic Mode

    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 39

    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 40

    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 41

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 39 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.

  • Page 42

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description 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 43: Operation

    OPERATION 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.

  • Page 44

    OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 2. Check the oil level. See page 69. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

  • Page 45: Pre-ride Inspection

    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. Item Remarks Page Brake system/pedal travel Ensure proper operation Brake fluid Ensure proper level...

  • Page 46: Starting The Engine

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

  • Page 47: Stopping The Engine

    OPERATION 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. WARNING A rolling vehicle can cause serious injury. Always engage the park brake after stopping the engine.

  • Page 48

    OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. 3. Practice starting and stopping (using the brakes) until you're famil- iar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.

  • Page 49: Driving Procedure

    OPERATION 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 50: Driving On Slippery Surfaces

    OPERATION 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 51: Driving Uphill

    OPERATION 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. 15° maximum 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn.

  • Page 52: Driving Downhill

    OPERATION Driving on a Sidehill (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 (15°...

  • Page 53: Driving Through Water

    OPERATION Driving Through Water WARNING 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 54: Driving Over Obstacles

    OPERATION 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.

  • Page 55: Driving In Reverse

    OPERATION 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 56: Parking On An Incline

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

  • Page 57: Hauling Cargo

    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: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 58

    Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities Cargo Box (Level Ground) RANGER 4X4 700 EFI 1500 lbs. (681 kg) 1000 lbs. (454 kg) WARNING Driving with passengers in the...

  • Page 59: Dumping The Cargo Box

    OPERATION 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 creating hazardous driving conditions.

  • Page 60: Towing Loads

    OPERATION 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 bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing.

  • Page 61: Parking The Vehicle

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

  • Page 62

    OPERATION 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 differen- tial. Press the top of the rocker switch to engage All Wheel Drive (AWD).

  • Page 63: 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 automati- cally disengage.

  • Page 64: Emission Control Systems

    EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 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.

  • Page 65: Maintenance

    MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. 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.

  • Page 66: Periodic Maintenance Chart

    MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key 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. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.

  • Page 67

    MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering Pre-Ride Make adjustments as need ed. See Pre-Ride Checklist Front suspension Pre-Ride on page 42. Rear suspension Pre-Ride Tires...

  • Page 68

    MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine breather 25 H Monthly Inspect; replace if necessary filter (if equipped) Engine oil change 25 H Perform a break-in oil change (break-in) at one month Park brake cable 25 H Check tension, adjust...

  • Page 69

    MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Fuel system 100 H 12 M Check for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; replace lines every two years Fuel filter 100 H 12 M Replace yearly...

  • Page 70

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

  • Page 71: Engine Oil

    MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil.

  • Page 72

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine. 1.

  • Page 73

    MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause 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 62. Always change the oil filter whenever changing oil.

  • Page 74

    MAINTENANCE Engine Oil Oil and Filter Change 12. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 13. Shift the transmission to neutral. 14. Apply the brakes. Engage the park brake. 15. Start the engine. Allow it to idle for one to two minutes. 16.

  • Page 75: Specifications

    MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 43.6 oz. 14 ft. lbs. 14 ft. lbs. (Transmission) Synthetic (1290 ml) (19.4 Nm) (19.4 Nm) Gearcase Lube Front Gearcase Premium Demand 9.3 oz.

  • Page 76

    MAINTENANCE 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 77: Polaris Products

    MAINTENANCE Gearcases Front Gearcases Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications.

  • Page 78

    MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products.

  • Page 79: Spark Plugs

    MAINTENANCE Spark Plugs NOTICE 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 110. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER .035"...

  • Page 80

    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 81: Cooling System

    MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.

  • Page 82

    MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 62. 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: Radiator Coolant Level

    MAINTENANCE 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 62. 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 84

    MAINTENANCE 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.

  • Page 85

    MAINTENANCE Polaris Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced.

  • Page 86: Pvt Drying

    MAINTENANCE 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.

  • Page 87: Vehicle Immersion

    MAINTENANCE Vehicle Immersion NOTICE 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 88: Air Filter

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. 1. Lift the cargo box to access the air box. 2. Remove the air box Air Filter cover and inspect the gasket.

  • Page 89

    MAINTENANCE 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 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 90

    MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs located on the bottom of the muffler. 2. Shift the transmission to neutral. Apply the brakes. Start the engine.

  • Page 91: Throttle Freeplay

    MAINTENANCE Throttle System WARNING 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 92: 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 93: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 31. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown.

  • Page 94: 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 95: Park Brake Adjustment

    MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause illumination of the park brake light and activation of the limiting feature.

  • Page 96

    MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus- pension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting holes. 2. Reposition the shocks to the outside mounting holes. 3.

  • Page 97: Tire Tread Depth

    MAINTENANCE Tires WARNING 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 98: Wheel Removal

    MAINTENANCE Tires WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.

  • Page 99: Headlight Lamp Replacement

    MAINTENANCE 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 100: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 25 ft. (7.6 m) 8" (20 cm) 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.

  • Page 101

    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 102: Battery Removal

    MAINTENANCE Battery WARNING 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 103: 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 102 before installing the battery.

  • Page 104: Battery Storage

    MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

  • Page 105

    MAINTENANCE 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 99. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

  • Page 106

    MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required...

  • Page 107: Cleaning And Storage

    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces.

  • Page 108: Polishing The Vehicle

    MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow- ing items: •...

  • Page 109

    MAINTENANCE 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 110: Battery Maintenance

    MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 104.

  • Page 111: Fluid Levels

    MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 62. • Front and rear gearcase fluid • Transmission fluid • Brake fluid (change every two years and any time the fluid looks dark or contaminated) •...

  • Page 112: Removal From Storage

    MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. 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.

  • Page 113: Specifications

    SPECIFICATIONS RANGER 4X4 700 EFI Maximum Weight Capacity 1500 lbs. (681 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1237 lbs. (561 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.25 qts.

  • Page 114

    SPECIFICATIONS RANGER 4X4 700 EFI Lubrication System Pressurized Wet Sump Engine Oil 2W-50 Driving System Type PVT, 4-wheel independent shaft, lockable differ- ential Shift Type Single Lever (H/L/N/R) Gear Reduction - Low 7.49:1 Gear Reduction - Reverse 6.81:1 Gear Reduction - High 3.05:1...

  • Page 115: Polaris Products

    POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) 2871653...

  • Page 116: Troubleshooting

    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 48. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently.

  • Page 117

    TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or Disconnect the connector if temporary switch movement or failure continued operation is necessary, see your dealer promptly for service Engine Doesn't Turn Over Possible Cause...

  • Page 118

    TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...

  • Page 119

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range...

  • Page 120: Warranty

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- 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.

  • Page 121

    WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.

  • Page 122

    WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.

  • Page 123

    WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the 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: Maintenance Log

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

  • Page 125

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 126

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 127: Index

    INDEX Accessory Outlets ....24 Cap, Fuel ..... . 30 Adding Coolant .

  • Page 128: Index

    INDEX Disengaging AWD ....60 Filter Systems ....85 Downloading Blink Codes ..38-39 Filter, Air .

  • Page 129: Oil Change

    INDEX Idle Speed ....89 Main Gearcase Lubrication ..72 Ignition Switch....26 Main Gearcase Oil Change .

  • Page 130

    INDEX Park Brake..... 28 Safety Decals ....5-7 Park Brake Adjustment .

  • Page 131

    INDEX Suspension Adjustment, Rear ..93 Vehicle Identification Numbers..4 Switches....26-27 Vehicle Immersion .

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