Polaris 4X4 700 EFI manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e p roudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excell ence for a ll[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS V ehicle Identification Numbers . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F eatures and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Emission Control Systems . . . . . . . . . . . . . . . 57 M[...]

4 VEHICLE IDENTIFICA TION NUMBERS Record your vehicle's identificatio n numbers and key numb er 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 k ey number) and mating it with o ne of your existing keys. The ignition switch must be rep[...]

5 SAFETY Safety Decals and Locations W arning de cals have been placed on the vehicle fo r your protection. Read and follow the instructions of the decals on the vehicle carefully . If any of the decals depicted in this ma nual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle . If any deca[...]

6 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. T o 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 seriou s injury or de[...]

7 SAFETY Safety Decals and Locations Shift Caution CAUTION T o avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary W arning WARNING Improper vehicle use can result in SEVERE INJURY or DEA TH. NEVER: • Operate on public roads. A collision can occur with a another vehicle. • Carry more than two passengers, [...]

8 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger in this vehicle. Know Y our V ehicle As the operator of the vehicle, y o u are responsible for your p ersonal safety , the safety of others, and th e prot[...]

9 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

10 SAFETY Operator Safety • Read this manual and all labels ca refully . Follow the operat ing proce- dures described. • Never allow anyone without a valid driver's license to operate this vehicle. • Minimum age recommendation for passengers is five years old. Pas- sengers under five years of age require special restraints which are not [...]

11 SAFETY Operator Safety • Always follow proper procedures for turning as described in this manual. Practice turning at slow spee ds 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 vehicl[...]

12 SAFETY Operator Safety • Never modify this vehicle throug h improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo sh ould be properly distributed and securely attached. Reduce speed and fol- low the instructions in this manu al for hauling cargo or pulling a trailer . Allow a greater dis[...]

13 SAFETY Operator Safety Equipment Modifications W e are co ncerned for the safety of our customers and for the general public. Therefore, we strongly reco mmend 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 fo r these purposes. An[...]

14 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Stalling, rolling b ackwards while climbing a hill WHA T CAN HAPPEN V ehicle overturn HOW TO A VOID 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 en[...]

15 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this vehicle wit hout prop er instruction WHA T CAN HAPPEN Loss of control, accident HOW TO A VOID THE HAZARD The risk of an accident is greatly increased if th e operator does not know how to opera te the vehicle properly i n different situations and on different types of terrain. Al[...]

16 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this vehicle after consum ing alcohol or drugs WHA T CAN HAPPEN Could seriously a ffect your judgment. Could cause you to react more slowly . Could affect your balance and perception. Could result in an accident. HOW TO A VOID THE HAZARD Driving a RANGER requires your full attention. [...]

17 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Attempting jumps and other stunts WHA T CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO A VOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WAR N I N G POTENTIAL HAZARD Operating on frozen b odies of water . WHA T CAN HAPPEN Severe injury or dea[...]

18 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD F ailure to inspect the vehicle before ope rating F ailure to properly maintain the vehicle WHA T CAN HAPPEN Accident, equipment damage HOW TO A VOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow the inspection and mainte[...]

19 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD F ailure to follow the minimu m age recommendations fo r this vehicle WHA T CAN HAPPEN Serious injury or death (the child or others) HOW TO A VOID THE HAZARD Only persons with a valid driver's license shou ld operate a Polaris RANGER . Even though a child may be within the age group for wh[...]

20 SAFETY Operator Safety WAR N I N G Leaving the keys in the ignition can lea d to unauthorized use of the vehicle resulting in serious injury or death. Always re move the ignition key when the vehicle is not in u se. WAR N I N G After any overturn or accident, have a qualified service dea ler inspect the entire vehicle for possible damage, includ[...]

21 SAFETY F uel Safety WAR N I N G Gasoline is highly flammable and is explosive under certa in conditions. Always exercise extreme caution w henever handling gasoli ne. Always stop the engine when refu eling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refu eling area or where ga [...]

22 FEA TURES AND CONTROLS Component Locations Some Polaris vehicles are equipped wi th special feature s such as the cab frame. Not all models come with all fe atures. Refer to the specifications section beginning on page 108. Cab F rame (if Equipped) Console Steering Wheel Hip Bar F uel T ank Cap Seat Belts Cargo Box Battery (under hoo d) Seat Sto[...]

23 FEA TURES AND CONTROLS Component Locations Headlights Hood Hold-Down Strap F ront Bumper/Brush Guar d Radiator (if equipped )[...]

24 FEA TURES AND CONTROLS Component Locations T railer Hitch Bracket This vehicle is equipped with a recei ver hitch bracket for a trailer hitch. T railer towing equipment is no t supplied with this vehicle. T o avoid injury and pro perty damage, always heed the warnings and towing capacities outlin ed on pages 50-53. T a ilgate Latch Release T a i[...]

25 FEA TURES AND CONTROLS Component Locations Instrument Cluster Yo u r RANGE R 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, ho urs of operation and engine RPM. Refer to page 34 for the location of the instrument cluster . NOTE: In a[...]

26 FEA TURES 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 cl uster may have shut off to protect th[...]

27 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedome ter to toggle through the mode op tions. See page 34. Odometer Mode The odomete r records the miles traveled by the v ehicle. T rip Meter Mode The trip meter records the miles travel ed by the vehicle on each tr[...]

28 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the [...]

29 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Scr een V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. A WD Diagnostic Screen The gauge indicates whether or not cu rrent is flowing through the A WD coil (only on models with switc[...]

30 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle 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 Informatio[...]

31 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your Polaris dealer fo r all major repairs. See page 32 for Blink Co des and Failu re Descriptions. Use the follow- ing procedure to downlo ad blink codes (failure codes) from the EFI modul[...]

32 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Description -- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Gr ound 22 TPS: Short Circuit to Battery 23 RAM Error:[...]

33 FEA TURES AND CONTROLS 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. Fu e l C a p The fuel tank filler cap is located on the right-hand sid[...]

34 FEA TURES AND CONTROLS Console Auxiliary Outlet The 12-volt accessory plug receptacle has spade co nnections on the back that may be used to po wer an auxiliary light or other o ptional accessories or lights. The connections are behind the console, under the hood. Mode Button The yellow button located di rectly under the speedometer is used to t[...]

35 FEA TURES 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 ha rd- packed surfaces with light loads. T o change gears, stop the vehicle, and with the engi ne idling, move the lever to the desired gear . Do not attempt to shift ge[...]

36 FEA TURES AND CONTROLS Brake P edal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle P edal 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 startin g the engine.[...]

37 FEA TURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated s witch. The key can be removed from the switch when it is in the OFF position. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has three positions: high beam, low beam and of f. AW[...]

38 OPERA TION V ehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it take s to use the first two tanks ful l of gasoline. No single action on your part is as important as a proper break- in period. Careful treatm ent of a new engine will result in more efficient performance an[...]

39 OPERA TION Pre-Ride Inspection WAR N I N G If a proper inspection is not done befor e ea ch use, severe i njury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition. Item Remarks P age Brake system/pedal travel En sure proper operation 36 87 Brake fluid Ensure proper level 87 F ront[...]

40 OPERA TION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt. 2. Engage the park brake. 3. Shift the transmission to neutral. 4. Apply the brake s. NOTE: Do not pre ss the throttle peda l while starting the en gine. 5. T urn the ignition key past the ON/RUN position to ST AR T . Engage the starter for a maximum of fiv[...]

41 OPERA TION Stopping the Engine 1. Release the throttle pedal complete ly and brake to a complete stop. 2. T urn the engine off. 3. Engage the park brake. Braking 1. Release the throttle pedal completely . 2. Press on the brake pedal evenly and firmly . NOTE: Practice starting and stopping (usin g the brakes) until you're familia r with the [...]

42 OPERA TION 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 surroun dings and determine your path of travel. 4. Release the park brake. 5. Keeping both hands on the s[...]

43 OPERA TION 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 slidin g. Under these con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertne ss, reading the trail and avoi[...]

44 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void steep hills (15 ° maximum). 3. Keep both feet on the floor . 4. Procee d at a steady rate of speed and throttle opening. WAR N I N G Climbing hills imprope rly can cause loss of contro l or vehicle overturn. [...]

45 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brake s slightly to aid in slowing. WAR N I N G Crossing hillsides or turning on hills c an result in loss of control or vehicl e overturn, resulting in sev[...]

46 OPERA TION Driving Safely Driving Through W ater Yo u r P o l a r i s RANGER can operate through water up to a maximum recommended de pth equal to the floor- boards. Follow these procedures when oper- ating through water: 1. Always determine water depths and current before entering. 2. Choose a crossing where both banks have gradual inclines. 3.[...]

47 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and lear n to re ad the terrain you're traveling on. W atch for hazards such as logs, rocks and low hanging branches. WAR N I N G Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obstacles are immedia tely visible[...]

48 OPERA TION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the brak es lightly for stopping. 3. A void tu rning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always inspect left an d right fields of vision before backing. WAR[...]

49 OPERA TION Driving Safely P arking on an Incline A void parking o n an incline if poss ible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear . 2. Engage the park brake. 3. T urn the engine off. 4. Block the rear wheels on the downhill side. WAR N I N G A rolling vehicle can ca use property damage and serious[...]

50 OPERA TION Driving Safely Hauling Cargo WAR N I N G Hauling cargo imprope rly can alter vehicle handling and may cause loss of control or brake instability , whi ch can result in serious injury or death. Always follow these p recautions when ha uling cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO . Always load [...]

51 OPERA TION 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 Max imum Capacities (Level Ground) Cargo B ox RANGER 4X4 EFI 1500 lbs. (681 kg) 1000 lbs. (454 kg) RANGER 6X[...]

52 OPERA TION Driving Safely Dumping the Cargo Box 1. Select a level site to dump the car go box. Do not attempt to dump or unload the vehicle while parke d on an incline. 2. Engage the park brake. 3. Dismount the vehicle. 4. Ensure that the cargo is positioned evenly or toward the front of the carg o box. 5. Release the tailgate by pulling up on t[...]

53 OPERA TION Driving Safely T owing Loads Belt Life T o extend belt life, use the lowest gear po ssible when hauling or towing heavy cargo. WAR N I N G T owing improperly can alter vehicle handling and may cause l oss of control or brake instability , which can result in serio us injury or death. Always follow these precautions when towing: Never [...]

54 OPERA TION Driving Safely P arking the V ehicle 1. Stop the vehicle on a level surface. 2. T urn the engine off. 3. Engage the park brake. 4. Remove the ignition switch key to prevent unauthorized use. WAR N I N G A rolling vehicle can cause property damage and serious injury . Always engage the park brake after stopping the engine. WAR N I N G [...]

55 OPERA TION 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 dif ferential. Locking the differential in slippery or low traction conditions helps improve traction. Press the top of the rocker switch to enga[...]

56 OPERA TION All Wheel Drive (A WD) The illuminated amber A WD switch indicates that the vehicle is in A WD. When the A WD 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. There is no limit to the length of time the [...]

57 EMIS SION 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. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that wa s tested and qual[...]

58 MAINTENANCE P eriodic 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 main tenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

59 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Q Have an authorized Polaris dealer perform these services. WAR N I N G Improperly performing the p rocedures marked with a Q coul d result in compone[...]

60 MAINTENANCE P eriodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission Control System Serv ice - 4 Cycle (California ) Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever [...]

61 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission Control System Serv ice - 4 Cycle (California ) Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Engine breather filter [...]

62 MAINTENANCE P eriodic Maintenance Char t X Perform these procedures more often fo r vehicles subjected to severe use. E Emission Control System Serv ice - 4 Cycle (California ). Q Have an authorized Polaris dealer perform these services Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q E F uel system 100 H 12 [...]

63 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 5 8, or more often under severe use, such as wet or dusty cond itions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil Pola[...]

64 MAINTENANCE Lubrication Recommendations 4X4 6X6 Swing Arm Bushings 6X6 Prop Shaft U-Joints 4X4 6X6 6X6 Ball Joint 6X6[...]

65 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Ch art beginning on page 5 8. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's[...]

66 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Alway s use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine. 1. Position the vehicle on a level surface. 2. Apply the brakes. Start the engine and allow it to idle [...]

67 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area [...]

68 MAINTENANCE Engine Oil Oil and Filter Change 1. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended o il. 2. Shift the transmission to neutral. 3. Engage the park brake. 4. Apply the br akes. Star t the engine. Allow it to idle for one to two minutes. 5. Stop the engine. Inspect for leaks. 6. Re-check the oil level on [...]

69 MAINTENANCE Gearcases T ransmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 58. Maintain the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specific ations Chart on page 68 for recommended lubricants, capacities and to[...]

70 MAINTENANCE Gearcases T ransmission (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 pla te. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the dr ain plug. Drain the oil. Dispose of used oil properly . 3. W ipe the magneti[...]

71 MAINTENANCE Gearcases F ront Gearcases Always check and change the front g earcase oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 58. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specific ations Chart on page 68 for recommended lubricants, capacities and torqu[...]

72 MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle gearcase oil at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 58 . Maintain the oil level even with the botto m thread of the fill plug hole. Refer to the Gearcase Specific ations Chart on page 68 for recommended lubricants, capacities [...]

73 MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Refer to the Gearcase Specific ations Chart on page 68 for recommended lubricants, capacities and torque spec ifications. See page 1 12 for the part numbers of Po laris products. The [...]

74 MAINTENANCE Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan unde r 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. T orque to specifica- tion. 5. Add the recommended oil. 6. Reinstall the fill plug. T orque to specification[...]

75 MAINTENANCE Spark Plugs Spark Plug Gap/T orque Spark plug condition is indicative of engine operation. The spark plug firing end condi tion should be read after the engine is warmed up and the vehicle is driven at higher speed s. Immediately check the spark plug for correct color . See page 76. CA UTION Using non-recommended spark plugs can resu[...]

76 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray , ta n 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 no t be white. A white insulator tip in dicates overh[...]

77 MAINTENANCE Cooling System Operation The engine coolant level is controlled or mainta ined by the recovery system. The recovery system componen ts are the overflow bottle, radia- tor filler neck, radiator pr essure cap and connecting hose. As coolant operating temperature increases, the expa nding (heated) excess coolant is forced out of the rad[...]

78 MAINTENANCE Cooling System Radiator and Cooling F an Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiat or or behind the cooling fan. Inter-[...]

79 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiat or or behind the cooling fan. Inter- fe[...]

80 MAINTENANCE P olaris V ariable T ran smission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts , wears clutch components and causes ou ter clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT componen ts (belt, cover , etc.). When T o Use Low Range and High[...]

81 MAINTENANCE PVT System WAR N I N G F ailure 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 failu re may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be ou[...]

82 MAINTENANCE PVT System PVT Drying There may be some instances when wate r 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. T ighten the screws. 4. Apply the brakes. Star t the engine. 5. Engage th[...]

83 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginn ing on page 58. 1. Lift the car go box to access the air box. 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter . 4. Do[...]

84 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge accumulated carbon from the exha ust 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. 3. Purge accumulated carbon from the system by momentarily rev- ving the [...]

85 MAINTENANCE Throttle System Throttle F reeplay If the throttle pedal has excessive play due to c able stretch or mis- adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully . If the throttle pedal has no freeplay , the throttle may be hard to control, and the idle speed may be[...]

86 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Polaris dealer for adjustment. Throttle F reeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster . 3. Squeeze the end of the rub- ber boot and sli de it far enough to ex[...]

87 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36 . Brake Fluid Inspect the brake syste m 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 [...]

88 MAINTENANCE Brakes Brake Inspection 1. Check the br ake 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 . 5. Change pads wh en worn to 3/64" (1 mm). P ark Brake Inspecti[...]

89 MAINTENANCE Steering Wheel Inspection Check the steering wheel for s pecifie d freeplay and smooth op eration at the intervals outlined in the Period ic Maintenance Chart beginning on page 58. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0 " (20-25 mm) of freeplay[...]

90 MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before ea ch use of the vehicle. 1. Push the latch plate into the buck le until it clicks. The latch plate must slide smoothly in to the buckle. A click indicates that it's securely latched. 2. Push the red button in the middle of the buckle to make sure it releases fr[...]

91 MAINTENANCE Tires Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut T orque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or the lug nut. WAR N I N G Operating your vehi[...]

92 MAINTENANCE Tires Wheel Removal 1. Stop the engine. Place the transm ission in gear . Engage the park brake. 2. Loosen the wheel nuts slightly . 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmis- sion in gear . 2. Engage[...]

93 MAINTENANCE Lights When servicing a halog en 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. Headlight Lamp Replacement 1. Open the hood. 2. Unplug the headlamp from the wiring harness. Be sure to pull on the co nnector , not on the wiring. 3. T ur[...]

94 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 floo r to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. T urn on the headlights. 4. Observe the h[...]

95 MAINTENANCE V ehicle Immersion If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicle to dry land or at the very least, to water below the footrests. 2. Dry any water present in the a ir box. 3. Filter replacement is required if water is present. 4. Thoroughly dry the a[...]

96 MAINTENANCE Battery Y our 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 conne[...]

97 MAINTENANCE Battery Battery Removal 1. Open the hood. 2. On conventional batteries, remove the batte ry vent tube. 3. Disconnect the black (nega- tive) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery side- ways, which could spill elec- [...]

98 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 100 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in th[...]

99 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to maintain a full charge. See page 100. N[...]

100 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electrolyt e during charging. See page 97. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.270 [...]

101 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 h ours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cur rent charger @ standard amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None require[...]

102 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleaning[...]

103 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •B r[...]

104 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “lik e new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coasta l areas) are more susce ptible to corrosion if no t properly clean ed.[...]

105 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 102. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel S tabilizer . Follow the instructions on th e container for the rec ommended amount. NOTE: Carbon C[...]

106 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. T reat the fuel system with Pola ris Carbon Clean. Follow the instruc- tions on the container . Start the engine. Allow it to idl e for several minutes so the Carbon Clean re aches the injectors. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Syn- t[...]

107 MAINTENANCE Removal from Storage 1. Check the battery electrolyte leve l and char ge 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. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points l[...]

108 SPECIFICA TIONS RANGER 4X4 EFI Gross V ehicle W eight 2750 lbs. (1247 kg) Fuel Capacity 9 gal. (34 l) Engine Oil Capacity 2 qts. (2.1 l) Coolant Capacity 3.25 qts. (3 l) T owing Capacity 1500 lbs. (681 kg Hitch T ongue Capacity 150 lbs. (68 kg) Max. Cargo Box Load 1000 lbs. (454 kg) Overall Length 1 13 in. (282 cm) Overall W idth (box) 60 in. ([...]

109 SPECIFICA TIONS NOTE: See your Polaris dealer for clutchin g specifications. RANGER 4X4 EFI Lubrication System Pressurized W et Sump Engine Oil 0W/40 Driving System T ype PVT , 4-wheel independent shaft, lockable dif fer- ential Shift T ype Single Lever (H/L/N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High [...]

110 SPECIFICA TIONS RANGER 6X6 EFI Gross V ehicle W eight 2900 lbs. (1317 kg) Fuel Capacity 9 gal. (34 l) Engine Oil Capacity 2 qts. (2.1 l) Coolant Capacity 3.25 qts. (3 l) T owing Capacity 1750 lbs. (794 kg) Max. Cargo Box Load 1250 lbs. (567 kg) Overall Length 120 in. (304.8 cm) Overall W idth (box) 60 in. (152.4 cm) Overall W idth (tires) 58 in[...]

111 SPECIFICA TIONS NOTE: See your Polaris dealer for clutchin g specifications. RANGER 6X6 EFI Lubrication System Pressurized W et Sump Engine Oil 0W/40 Driving System T ype PVT Shift T ype Single Lever , Console (H/L /N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.9:1 Gear Reduction - High 3 .14:1 Drive Ratio - Front: 3.83:1 Drive Ra[...]

112 POL ARIS PRODUCTS Pa rt N u m b e r Description Engine Lubr icant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Pre mium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Pre mium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / T ransmission Lubricants 2873602 Pre mium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Pre mium AGL Synth[...]

113 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range. See wa rnings on page 44. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequently . See page 80. Insu[...]

114 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Loose electronic control box connections Insp[...]

115 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Re place with re commended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs I[...]

116 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Insp ect, clean and/or replace spark p lug W orn or defective spark plug wires See your dealer Incorrect spark plug gap or hea[...]

117 WA RRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polari s also gives a one year lim ited warranty on the final drive chain for failure due to defects. This warr anty covers the parts and l[...]

118 W ARRANTY LIMIT A TIONS OF WARR ANTIES AND REMEDIE S ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY P ERIOD. POLARIS FUR THER DISCLAIMS AL L EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . [...]

119 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

120 W ARRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Off Road Utilit y V ehicle (ORUV) emissions limited warranty is in additi on to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the [...]

121 WA RRANTY California Emission Control W arranty Statement Y our W arranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2005 and later Lar ge Spark Ignition Engine ([...]

122 W ARRANTY California Emission Control W arranty Statement Owner's W arranty Responsibilities: • As the LSI engine owner , you are responsib le for the performance o f the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you reta in all receipt[...]

123 WA RRANTY California Emission Control W arranty Statement Emission-Related P arts Covered Under This W arranty (1) Fuel Metering System (i) Carburetor and internal pa rts (and/or pressure reg ulato r or fuel injection system) (ii) Air/fuel ratio feedback an d control system, if applicable (iii) Cold start enrichment system, i f applicable (iv) [...]

124 W ARRANTY California Emission Control W arranty Statement What is Not Covered Under This W arranty This warranty does not cover a ny emission-related part whic h malfunctions, fails or is damaged due to altera tions and/or modifications such as changing, adding or removing parts. When the LSI engine is being serviced un der warranty , POLARIS a[...]

125 WA RRANTY X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services Repair and Replacement of Emission-Related P arts It is recommended that only LSI en gine replacement parts, which have been authorized and app roved by POLARIS, should be [...]

126 MAINTENANCE L OG Use the following chart to r ecord periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

127 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

128 INDEX A Accessory Outlet . . . . . . . . . . . . . . . 34 Adding Coolant . . . . . . . . . . . . . . . . 77 Adjustment, Headli ght Beam. . . . . . 94 Adjustment, Park Brake . . . . . . . . . . 88 Adjustment, Rear Spri ng . . . . . . . . . 89 Adjustment, Rear Suspen sion . . . . . 89 Adjustme nt, Throttle Freeplay . . . . . 86 Age Restrictions .[...]

129 INDEX D Driving on Slippery Surfa ces . . . . . . 43 Driving Over Ob stacles . . . . . . . . . . 47 Driving Proce dure . . . . . . . . . . . . . . . 42 Driving Safely . . . . . . . . . . . . . . . 42-54 Driving Through Water . . . . . . . . . . 46 Driving Uphill . . . . . . . . . . . . . . . . . . 44 Driving, After Driving in Water . . . . 82 D[...]

130 INDEX L Lamp Replacemen t, Headlight . . . . 93 Level, Coolant . . . . . . . . . . . . . . . 78-79 Light Switch. . . . . . . . . . . . . . . . . . . 37 Lights . . . . . . . . . . . . . . . . . . . . . . 93-94 Lights, Brake . . . . . . . . . . . . . . . . . . 94 Load Capacity . . . . . . . . . . . . . . . . . 51 Loads, Towing . . . . . . . . . .[...]

131 INDEX R Receiver Hitch . . . . . . . . . . . . . . . . . 24 Release, Pa rk Brake . . . . . . . . . . . . . 36 Removal, Battery . . . . . . . . . . . . . . . 97 Removal, Seat . . . . . . . . . . . . . . . . . . 33 Removal, Wheels . . . . . . . . . . . . . . . 92 Removing the Vehicle from Storage 107 Replacement, Headlight Lamp . . . . . 93 Rever[...]