Polaris 4X4 700 EFI User Manual

7SAFETYSafety Decals and LocationsShift CautionCAUTIONTo avoid transmission damage, shift only when vehicle is stationary and at idle.Discretionary Wa

97MAINTENANCEBatteryBattery Removal1. Open the hood.2. On conventional batteries, remove the battery vent tube.3. Disconnect the black (nega-tive) bat

98MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It c

99MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

100MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

101MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after the end of charging.State of Ch

102MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

103MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

104MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

105MAINTENANCECleaning and StorageStorage TipsClean the ExteriorMake any necessary repairs and clean the vehicle as recommended. See page 102.Stabiliz

106MAINTENANCECleaning and StorageStorage TipsFog the Engine1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-tions on the contai

8SAFETYOperator SafetyAge RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. No person under

107MAINTENANCERemoval from Storage1. Check the battery electrolyte level and charge the battery if neces-sary. Install it in the vehicle. Make sure th

108SPECIFICATIONSRANGER 4X4 EFIGross Vehicle Weight 2750 lbs. (1247 kg)Fuel Capacity 9 gal. (34 l)Engine Oil Capacity 2 qts. (2.1 l)Coolant Capacity 3

109SPECIFICATIONSNOTE: See your Polaris dealer for clutching specifications.RANGER 4X4 EFILubrication System Pressurized Wet SumpEngine Oil 0W/40Drivi

110SPECIFICATIONSRANGER 6X6 EFIGross Vehicle Weight 2900 lbs. (1317 kg)Fuel Capacity 9 gal. (34 l)Engine Oil Capacity 2 qts. (2.1 l)Coolant Capacity 3

111SPECIFICATIONSNOTE: See your Polaris dealer for clutching specifications.RANGER 6X6 EFILubrication System Pressurized Wet SumpEngine Oil 0W/40Drivi

112POLARIS PRODUCTSPart Number DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (

113TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

114TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

115TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

116TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel RefuelKinked or plugged fuel vent line Inspect and replaceWater is pre

9SAFETYOperator SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these wor

117WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

118WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

119WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

120WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

121WARRANTYCalifornia Emission Control Warranty StatementYour Warranty Rights and ObligationsThe California Air Resources Board and Polaris Industries

122WARRANTYCalifornia Emission Control Warranty StatementOwner's Warranty Responsibilities:• As the LSI engine owner, you are responsible for the

123WARRANTYCalifornia Emission Control Warranty StatementEmission-Related Parts Covered Under This Warranty(1) Fuel Metering System (i) Carburetor and

124WARRANTYCalifornia Emission Control Warranty StatementWhat is Not Covered Under This WarrantyThis warranty does not cover any emission-related part

125WARRANTYX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service.Q Have an authorized Polaris dealer p

126MAINTENANCE LOGUse the following chart to record periodic maintenance.DATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

10SAFETYOperator Safety• Read this manual and all labels carefully. Follow the operating proce-dures described.• Never allow anyone without a valid dr

127MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

128INDEXAAccessory Outlet . . . . . . . . . . . . . . . 34Adding Coolant . . . . . . . . . . . . . . . . 77Adjustment, Headlight Beam. . . . . .

129INDEXDDriving on Slippery Surfaces . . . . . . 43Driving Over Obstacles . . . . . . . . . . 47Driving Procedure. . . . . . . . . . . . . . . 42

130INDEXLLamp Replacement, Headlight . . . . 93Level, Coolant . . . . . . . . . . . . . . . 78-79Light Switch. . . . . . . . . . . . . . . . . . .

131INDEXRReceiver Hitch . . . . . . . . . . . . . . . . . 24Release, Park Brake . . . . . . . . . . . . . 36Removal, Battery . . . . . . . . . .

11SAFETYOperator Safety• Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to

12SAFETYOperator Safety• Never modify this vehicle through improper installation or use of accessories.• Never exceed the stated load capacity for thi

13SAFETYOperator SafetyEquipment ModificationsWe are concerned for the safety of our customers and for the general public. Therefore, we strongly reco

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards while climbing a hillWHAT CAN HAPPENVehicle overturnHOW TO AVOID THE HAZARDM

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle without proper instructionWHAT CAN HAPPENLoss of control, accidentHOW TO AVOID TH

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle after consuming alcohol or drugsWHAT CAN HAPPENCould seriously affect your judgme

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDAttempting jumps and other stuntsWHAT CAN HAPPENLoss of control, accident and/or vehicle overturnHOW TO

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to inspect the vehicle before operatingFailure to properly maintain the vehicleWHAT CAN HAPPENAc

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to follow the minimum age recommendations for this vehicleWHAT CAN HAPPENSerious injury or death

20SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Alway

21SAFETYFuel SafetyWARNINGGasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling ga

22FEATURES AND CONTROLSComponent LocationsSome Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all

23FEATURES AND CONTROLSComponent LocationsHeadlightsHoodHold-DownStrapFront Bumper/Brush GuardRadiator(if equipped)

24FEATURES AND CONTROLSComponent LocationsTrailer Hitch BracketThis vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer tow

25FEATURES AND CONTROLSComponent LocationsInstrument ClusterYour RANGER is equipped with an instrument cluster that senses vehi-cle speed from the rig

26FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

WARNINGRead, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.Failure to follow the safe

27FEATURES AND CONTROLSInstrument ClusterRider Information CenterStandard ModesUse the yellow mode button located under the speedometer to toggle thro

28FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe wrench icon will display when the gauge is in the diagnostic mode.

29FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeBattery Voltage ScreenView this screen to check battery voltage level.

30FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeProgrammable service intervalTo enable or disable the service interval

31FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesThe EFI diagnostic mode is for informational purposes only. Please s

32FEATURES AND CONTROLSInstrument ClusterRider Information CenterDownloading CodesBlinkCodeFailure Description-- No RPM Signal21 Loss of Synchronizati

33FEATURES AND CONTROLSSeat RemovalPull up on the front of the seat and slide it toward the front of the vehicle.Install the seat by sliding the tabs

34FEATURES AND CONTROLSConsoleAuxiliary OutletThe 12-volt accessory plug receptacle has spade connections on the back that may be used to power an aux

35FEATURES AND CONTROLSGear SelectorH: High GearL: Low GearN: NeutralR: ReverseNOTE: Low gear is the primary driving range for the RANGER. High gear i

36FEATURES AND CONTROLSBrake PedalDepress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.Throttle PedalPush t

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURES AND CONTROLSSwitchesIgnition SwitchThe ignition switch is a three-position, key-operated switch. The key can be removed from the switch whe

38OPERATIONVehicle Break-In PeriodThe break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use

39OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehic

40OPERATIONStarting the Engine1. Sit in the driver's seat and fasten the seat belt.2. Engage the park brake.3. Shift the transmission to neutral.

41OPERATIONStopping the Engine1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake.Br

42OPERATIONDriving SafelyDriving Procedure1. Sit in the driver's seat and fasten the seat belt.2. After starting the engine and allowing it to wa

43OPERATIONDriving SafelyDriving on Slippery SurfacesWhen driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the poss

44OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15°

45OPERATIONDriving SafelyDriving on a Sidehill (Sidehilling)Driving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly d

46OPERATIONDriving SafelyDriving Through WaterYour Polari s RANGER can operate through water up to a maximum recommended depth equal to the floor-boa

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2006 Polaris Sales Inc. All information contained with

47OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as

48OPERATIONDriving SafelyDriving in ReverseFollow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3

49OPERATIONDriving SafelyParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the

50OPERATIONDriving SafelyHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, w

51OPERATIONDriving SafelyHauling CargoThe RANGER has been designed to carry or tow specific capacities. Always read and understand the load distributi

52OPERATIONDriving SafelyDumping the Cargo Box1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked

53OPERATIONDriving SafelyTowing LoadsBelt LifeTo extend belt life, use the lowest gear possible when hauling or towing heavy cargo.WARNINGTowing impro

54OPERATIONDriving SafelyParking the Vehicle1. Stop the vehicle on a level surface.2. Turn the engine off.3. Engage the park brake.4. Remove the ignit

55OPERATIONDifferential Lock (4X4 Models)Locking the DifferentialThe 4X4 rear axle is equipped with a lockable differential that allows the operator t

56OPERATIONAll 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

3TABLE OF CONTENTSVehicle Identification Numbers. . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

58MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

59MAINTENANCEPeriodic Maintenance ChartMaintenance Chart KeyX Perform these operations more often for vehicles subjected to severe use.E Emission Con

60MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

61MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission Control System Service -

62MAINTENANCEPeriodic Maintenance Chart X Perform these procedures more often for vehicles subjected to severe use.E Emission Control System Service -

63MAINTENANCELubrication RecommendationsCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on p

64MAINTENANCELubrication Recommendations4X46X6Swing Arm Bushings6X6Prop ShaftU-Joints4X46X66X6Ball Joint6X6

65MAINTENANCEEngine OilAlways check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always

66MAINTENANCEEngine OilAlways check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always use th

4VEHICLE IDENTIFICATION NUMBERSRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store

67MAINTENANCEEngine OilOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on

68MAINTENANCEEngine OilOil and Filter Change1. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec-ommended oil.2. Shift the transmis

69MAINTENANCEGearcasesTransmission (Main Gearcase)Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance C

70MAINTENANCEGearcasesTransmission (Main Gearcase)Oil ChangeThe drain plug is located on the bottom of the transmission. Access the drain plug through

71MAINTENANCEGearcasesFront GearcasesAlways check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginn

72MAINTENANCEGearcasesMiddle Gearcase (6X6)Always check and change the middle gearcase oil at the intervals out-lined in the Periodic Maintenance Char

73MAINTENANCEGearcasesRear GearcaseAlways check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning

74MAINTENANCEGearcasesRear GearcaseOil Change1. Remove the fill plug.2. Place a drain pan under the drain plug. Remove the drain plug. 3. Drain the oi

75MAINTENANCESpark PlugsSpark Plug Gap/TorqueSpark plug condition is indicative of engine operation. The spark plug firing end condition should be rea

76MAINTENANCESpark PlugsSpark Plug ConditionNormal PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion deposits. Th

5SAFETYSafety Decals and LocationsWarning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals o

77MAINTENANCECooling SystemOperationThe engine coolant level is controlled or maintained by the recovery system. The recovery system components are th

78MAINTENANCECooling SystemRadiator and Cooling FanAlways check and clean the screen and radiator fins at the intervals out-lined in the Periodic Main

79MAINTENANCECooling SystemRadiator Coolant LevelAlways check and clean the screen and radiator fins at the intervals out-lined in the Periodic Mainte

80MAINTENANCEPolaris Variable Transmission (PVT) SystemBelt slip is responsible for creating excessive heat that destroys belts, wears clutch componen

81MAINTENANCEPVT SystemWARNINGFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component

82MAINTENANCEPVT SystemPVT DryingThere may be some instances when water is accidently ingested into the PVT system. Use the following instructions to

83MAINTENANCEFilter SystemsAir FilterAlways change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. 1.

84MAINTENANCESpark ArrestorUse the following procedure to periodically purge accumulated carbon from the exhaust pipe.1. Remove the arrestor clean-out

85MAINTENANCEThrottle SystemThrottle FreeplayIf the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in

86MAINTENANCEThrottle SystemThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see you

6SAFETYSafety Decals and LocationsClutch Cover WarningWARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not o

87MAINTENANCEBrakesThe front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36.Brake FluidInspect the brake sys

88MAINTENANCEBrakesBrake Inspection1. Check the brake system for fluid leaks.2. Check the brake pedal for excessive travel or a spongy feel. 3. Check

89MAINTENANCESteering Wheel InspectionCheck the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic M

90MAINTENANCESeat BeltsInspect all three seat belts for proper operation before each use of the vehicle.1. Push the latch plate into the buckle until

91MAINTENANCETiresTire Tread DepthAlways replace tires when tread depth is worn to 1/8" (3 mm) or less.Axle and Wheel Nut Torque SpecificationsIn

92MAINTENANCETiresWheel Removal1. Stop the engine. Place the transmission in gear. Engage the park brake.2. Loosen the wheel nuts slightly.3. Elevate

93MAINTENANCELightsWhen servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot

94MAINTENANCELightsHeadlight Beam Adjustment1. Place the vehicle on a level surface with the headlight approxi-mately 25 ft. (7.6 m) from a wall.2. Me

95MAINTENANCEVehicle ImmersionIf it's impossible to take your RANGER to a dealer before starting it, fol-low the steps outlined below.1. Move the

96MAINTENANCEBatteryYour vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can