Polaris 4X4 User Manual

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

97MAINTENANCECleaning and StorageStorage TipsClean the ExteriorMake any necessary repairs and clean the vehicle as recommended. See page 94.Stabilize

98MAINTENANCECleaning and StorageStorage TipsFog the Engine1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-tions on the contain

99MAINTENANCERemoval from Storage1. Check the battery electrolyte level and charge the battery if neces-sary. Install it in the vehicle. Make sure the

100SPECIFICATIONSRANGER 4X4 500 EFIGross Vehicle Weight 2700 lbs. (1226 kg)Dry Weight 1185 lbs. (537 kg)Overall Length 113 in. (282 cm)Overall Width (

101SPECIFICATIONSNOTE: See your Polaris dealer for clutching specifications.RANGER 4X4 500 EFILubrication System Dry SumpEngine Oil 0W/40Driving Syste

102POLARIS PRODUCTSPart Number DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (

103TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

104TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

105TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

106TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel RefuelKinked or plugged fuel vent line Inspect and replaceWater is pre

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

107WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

108WARRANTYLIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

109WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

110WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

111WARRANTYCalifornia Emission Control Warranty StatementYour Warranty Rights and ObligationsThe California Air Resources Board and Polaris Industries

112WARRANTYCalifornia Emission Control Warranty StatementOwner's Warranty Responsibilities:• As the LSI engine owner, you are responsible for the

113WARRANTYCalifornia Emission Control Warranty StatementEmission-Related Parts Covered Under This Warranty(1) Fuel Metering System (i) Carburetor and

114WARRANTYCalifornia Emission Control Warranty StatementWhat is Not Covered Under This WarrantyThis warranty does not cover any emission-related part

115WARRANTYX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service.Q Have an authorized Polaris dealer p

116MAINTENANCE LOGUse the following chart to record periodic maintenance.DATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

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

117MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

118INDEXAAdding Coolant . . . . . . . . . . . . . . . . 69AdjustmentHeadlight Beam . . . . . . . . . . . . 86Park Brake . . . . . . . . . . . . .

119INDEXEElectromagnetic Interference . . . . . . 51Emission Control, Crankcase . . . . . . 51Emission Control, Exhaust . . . . . . . . 51Emission

120INDEXMMain GearcaseLubrication. . . . . . . . . . . . . . . . 63Oil Change . . . . . . . . . . . . . . . . 64Oil Check . . . . . . . . . . . .

121INDEXSSpeed, Towing . . . . . . . . . . . . . . . . . 47Spring, Rear, Adjustment . . . . . . . . . 81Stabilizing the Fuel . . . . . . . . . . .

10SAFETYOperator Safety• Read this manual and all labels carefully. Follow the operating procedures described.• Never allow anyone without a valid dri

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 LocationsTailgateLatch ReleaseTaillightsAir BoxReceiver HitchCV Boot/Rear CaliperMuffler(Spark Arrestor)TaillightsTai

25FEATURES AND CONTROLSComponent LocationsIndicator LightsThe indicator light panel is located on the console. See page 28.Trailer Hitch BracketThis v

26FEATURES 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

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 CONTROLSSeat BeltsThe RANGER is equipped with lap-style seat belts for the operator and passenger.To wear the seat belt properly, follo

28FEATURES AND CONTROLSConsole Indicator LightsAWD/Differential SwitchCupHolderCupHolderStorageCompartment(with lid)12VAccessoryOutletStorageTrayIg

29FEATURES AND CONTROLSGear SelectorH: High GearL: Low GearN: NeutralR: ReverseNOTE: Low gear is the primary driving range for the RANGER. High gear i

30FEATURES AND CONTROLSBrake PedalDepress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.Throttle PedalPush t

31FEATURES AND CONTROLSSwitchesIgnition SwitchThe ignition switch is a three-position, key-operated switch. The key can be removed from the switch whe

32OPERATIONVehicle 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

33OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehic

34OPERATIONStarting Engine1. Sit in the driver's seat and fasten the seat belt.2. Engage the park brake.3. Shift the transmission to neutral.4. A

35OPERATIONStopping the Engine1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake.Br

36OPERATIONDriving SafelyDriving Procedure1. Sit in the driver's seat and fasten the seat belt.2. After starting the engine and allowing it to wa

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

37OPERATIONDriving SafelyDriving On Slippery SurfacesWhen driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the poss

38OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15°

39OPERATIONDriving SafelyDriving on a Sidehill (Sidehilling)Driving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly d

40OPERATIONDriving SafelyDriving Through WaterYour Polari s RANGER can operate through water up to a maximum recommended depth equal to the floor-boa

41OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as

42OPERATIONDriving SafelyDriving in ReverseFollow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3

43OPERATIONDriving SafelyParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the

44OPERATIONDriving SafelyHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, w

45OPERATIONDriving SafelyHauling CargoThe RANGER has been designed to carry or tow specific capacities. Always read and understand the load distributi

46OPERATIONDriving SafelyDumping the Cargo Box1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked

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

47OPERATIONDriving SafelyTowing LoadsBelt LifeTo extend belt life, use the lowest gear possible when hauling or towing heavy cargo.WARNINGTowing impro

48OPERATIONDriving SafelyParking the Vehicle1. Stop the vehicle on a level surface.2. Turn the engine off.3. Engage the park brake.4. Remove the ignit

49OPERATIONDifferential Operation ModesThe 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open d

50OPERATIONAll Wheel Drive (AWD)The illuminated amber AWD switch indicates that the vehi-cle is in AWD.When the AWD switch is on, the front gearcase w

51EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

52MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

53MAINTENANCEPeriodic Maintenance ChartMaintenance Chart KeyX Perform these operations more often for vehicles subjected to severe use.E Emission Con

54MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

55MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service.Q Have an

56MAINTENANCEPeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe use.E Emission-Related Service.Q Have an

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

57MAINTENANCELubrication RecommendationsCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on p

58MAINTENANCEEngine OilAlways check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always

59MAINTENANCEEngine OilAlways check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. We recommend

60MAINTENANCEEngine OilOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on

61MAINTENANCEEngine OilOil and Filter Change10. Reattach the oil line.11. Place shop towels beneath the oil filter. Using an oil fil-ter wrench, turn

62MAINTENANCEEngine OilOil and Filter ChangeOil Pump PrimingThis priming procedure must be performed whenever the oil hose connection between the oil

63MAINTENANCEGearcasesGearcase Specification ChartTransmission (Main Gearcase)Always check and change the transmission oil at the intervals outlined i

64MAINTENANCEGearcasesTransmission (Main Gearcase)Oil ChangeThe drain plug is located on the bottom of the transmission. Access the drain plug through

65MAINTENANCEGearcasesFront GearcaseAlways check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginni

66MAINTENANCEGearcasesRear GearcaseAlways check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning

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

67MAINTENANCESpark PlugsSpark Plug Gap/TorqueSpark plug condition is indicative of engine operation. The spark plug firing end condition should be rea

68MAINTENANCESpark PlugsSpark Plug ConditionNormal PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion deposits. Th

69MAINTENANCECooling SystemOperationThe engine coolant level is controlled or maintained by the recovery system. The recovery system components are th

70MAINTENANCECooling SystemRadiator and Cooling FanAlways check and clean the screen and radiator fins at the intervals out-lined in the Periodic Main

71MAINTENANCECooling SystemRadiator Coolant LevelAlways check and clean the screen and radiator fins at the intervals out-lined in the Periodic Mainte

72MAINTENANCEPolaris Variable Transmission (PVT) SystemWhen To Use Low Range vs. High RangeBelt slip is responsible for creating excessive heat that d

73MAINTENANCEPVT SystemPVT DryingThere may be some instances when water is ingested into the PVT sys-tem. Use the following instructions to dry it out

74MAINTENANCEFilter SystemsAir FilterAlways change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. 1.

75MAINTENANCEFilter SystemsBreather Filter and Hoses1. Lift the cargo box and locate the air box.2. Follow the right-hand breather line out the side o

76MAINTENANCESpark ArrestorUse the following procedure to periodically purge accumulated carbon from the exhaust pipe.1. Remove the arrestor clean-out

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

77MAINTENANCEThrottle SystemThrottle FreeplayIf the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in

78MAINTENANCEThrottle SystemThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see you

79MAINTENANCEBrakesThe front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30.Brake Flu

80MAINTENANCEBrakesBrake Inspection1. Check the brake system for fluid leaks.2. Check the brake pedal for excessive travel or a spongy feel. 3. Check

81MAINTENANCESteering Wheel InspectionCheck the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic M

82MAINTENANCESeat BeltsInspect all three seat belts for proper operation before each use of the vehicle.1. Push the latch plate into the buckle until

83MAINTENANCETiresTire Tread DepthAlways replace tires when tread depth is worn to 1/8" (3 mm) or less.Axle and Wheel Nut Torque SpecificationsIn

84MAINTENANCETiresWheel Removal1. Stop the engine. Place the transmission in gear. Engage the park brake.2. Loosen the wheel nuts slightly.3. Elevate

85MAINTENANCELightsWhen servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot

86MAINTENANCELightsHeadlight Beam Adjustment1. Place the vehicle on a level surface with the headlight approxi-mately 25 ft. (7.6 m) from a wall.2. Me

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

87MAINTENANCELightsBrake LightsWhen the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride. 1. Turn th

88MAINTENANCEBatteryYour vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can

89MAINTENANCEBatteryBattery Removal1. Open the hood.2. On conventional batteries, remove the battery vent tube.3. Disconnect the black (nega-tive) bat

90MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It c

91MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

92MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electroly

93MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after the end of charging.State of Cha

94MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend the

95MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

96MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life and