Polaris RANGER XP 4X4 700 EFI User Manual

7SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d

97MAINTENANCE AND LUBRICATIO NCleaning and StorageStorage TipsFog the Engine1. Treat the fuel system with Polaris Carbon Clean, following theinstructi

98MAINTENANCE AND LUBRICATIO NRemoval from Storage1. Check the battery electrolyte level and charge the battery ifnecessary. Install it in the vehicle

99POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

100SPECIFICATIONSRANGER 4X4 XPGross Vehicle Weight 2750 lbs. (1247 kg)Dry Weight 1185 lbs. (537 kg)Fuel Capacity 8gal.(30.3l)Engine Oil Capacity 2qts.

101SPECIFICATIONSRANGER 4X4 XPLubrication System Pressurized Wet SumpEngine Oil 0W/40Driving System Type PVT, 4-wheel independent shaft,lockable diffe

102SPECIFICATIONSRANGER 6X6 EFIGross Vehicle Weight 2900 lbs. (1317 kg)Dry Weight 1410 lbs. (640 kg)Fuel Capacity 8gal.(30.3l)Engine Oil Capacity 2qts

103SPECIFICATIONSRANGER 6X6 EFIFront Suspension MacPherson strutw/6.25 in. (15.9 cm) of travelCenter Suspension Independe ntw/5.25 in. (13.3 cm) of tr

104TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Turn OverPos

105TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

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

8SAFETYOperator SafetyS Always follow proper procedures for turning as described in thismanual. Practice turning at slow speeds before attempting t o

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 IM-PLIED WARRANTIES OF MERCHANTABILITY AND F

109WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NOWARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT ISSOLD O

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

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

112WARRANTYCalifornia Emission Control Warranty StatementOwner’s Warra nty Responsibilities:S As the LSI engine owner, you are responsible for the per

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

114WARRANTYWhat is Not Covered Under This WarrantyThis warranty does not cover any emission-related part which malfunctions, fails or isdamaged due to

115WARRANTYMaintenance Schedule Key" Perform these procedures more often for vehicles subjected to severe use.E Emission Control System Service (

116MAINTENANCE LOGPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / CO

9SAFETYOperator SafetyS Never modify this vehicle through improper installation or use ofaccessories.S Never exceed the stated load capacity for this

117MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

118INDEXAAge Restrictions 5...Air Filter 78...All Wheel Drive (AWD) 5 1...Auxiliary Outlet 26...A

119INDEXNNoise Emission Control System 52...OOil and Filter Change 62-63...Oil Check 61...Operator Safety 5-17...

10SAFETYOperator SafetyWARNINGMake sure your RANGER is in excellent operating condition at alltimes. We strongly recommend that the operator check all

11SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards whileclimbing a hillWHAT CANHAPPENVehicle overturnHOW TO AVOID THEHAZARDMain

12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfacesWHAT CANHAPPENLoss of controlHOW TO AVOID THEHAZARDThis vehicle’

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads or highwaysWHAT CANHAPPENCollision with another vehicleH

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle at excessive speedsWHAT CANHAPPENLoss of control, accidentHOW TO AVOID THEHAZARDA

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to inspect the vehicle before operatingFailure to properly maintain the vehicleWHAT CANHAPPENAcc

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to follow the minimum age recommendations for thisvehicleWHAT CANHAPPENSerious injury or death (

17SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always

18SAFETYSafety Decals and LocationsWarning decals have been placed on the RANGER for your protection.Read and follow the instructions of the decals on

19SAFETYSafety Decals and LocationsWARNINGS VEHICLE ROLLOVER could cause severe injury or death.This cab frame is not designed or intended to provide

20SAFETYSafety Decals and LocationsLocation 5 (under hood)56Location 6Location 7ATTENTIONS Operation of this vehicle without the air filterelement wil

21SAFETYSafety Decals and LocationsDiscretionary Warning Decal78

22SAFETYFuel SafetyWARNINGGasoline is highly flammable and is explosive under certainconditions. Always exercise extreme caution whenever handlinggaso

23FEATURES AND CONTROLSSome Polaris vehicles are equipped with special features such as thecab frame. Not all models come with all features. Refer to

24FEATURES AND CONTROLSComponent Locations12. Headlights13. Radiator (if equipped)14. Front Bumper/Brush Guard15. Hood Hold Down Strap14131215

25FEATURES AND CONTROLSComponent Locations16. Taillights17. Tailgate18. Tailgate Latch Release19. Muffler (Spark Arrester)20. CV Boot/Rear Caliper21.

26FEATURES AND CONTROLSIndicator Lights1. High Gear2. Low Gear3. Neutral Gear4. Reverse Gear5. High Temperature6. Park BrakeTrailer Hitch BracketThis

The engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.WARNING

27FEATURES AND CONTROLSFuel Cap/Fuel GaugeThe fuel tank filler cap (8) is located onthe right-hand side of the vehicle nearthe passenger seat. It has

28FEATURES AND CONTROLSSeat BeltsThe RANGER is equipped with lap-style seat belts for the operator andpassenger.WARNINGFalling from a moving vehicle c

29FEATURES AND CONTROLSConsole1. Cup Holder2. Indicator Lights3. Shift Lever4. Light S witch5. AWD/Differential Switch (if equipped)6. Hour Meter7. Gl

30FEATURES AND CONTROLSGear SelectorH: High GearL: Low GearN: NeutralR: ReverseNOTE: Low gear is the primarydriving range for theRANGER XP. High gear

12331FEATURES AND CONTROLSSwitchesIgnition Switch (1)The ignition switch is a three-position, key-operated switch. The keycan be removed from the swit

123432FEATURES AND CONTROLSBrake Pedal (1)Depress the brake pedal to slow or stop the vehicle.Apply the brakes while starting the engine.Throttle Peda

33OPERATIONVehicle Break-In PeriodThe break-in period for your new Polaris RANGER is the first twentyhours of operation, or the time it takes to use t

34OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

35OPERATIONStarting the EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness resulting in severe injury o

36OPERATIONStopping the Engine1. Release t he throttle pedal completel y and brake t o a complete stop.2. Turn the engine off.3. Engage the park brake

1WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wi de family of Polaris owners. We proudly produce an excitingline of uti

37OPERATIONDriving SafelyDriving Procedu res1. Sit in the driver’s seat and fasten the seat belt.2. After starting the engine and allowing it to warm

38OPERATIONDriving SafelyDriving On Slippery SurfacesWhen driving on slippery surfaces such as wet trails, loose gravel, orice, be alert for the possi

39OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15_

40OPERATIONDriving SafelySidehillingWARNINGCrossing hillsides or turning on hills can result in loss of control orvehicle overturn, resulting in sever

141OPERATIONDriving SafelyDriving Through WaterWARNINGThe large tires on your RANGER may cause the vehicle to float indeep or fast-flowing water, whic

42OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Watch for hazards such as logs,

43OPERATIONDriving SafelyDriving in ReverseFollow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3

44OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Place the t ransmi

45OPERATIONDriving SafelyHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and maycause loss of control or brake instability, wh

46OPERATIONDriving SafelyHauling CargoThe RANGER has been designed to carry or tow specific capacities.Always read and understand the load distributio

2Copyright 2005 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47OPERATIONDriving SafelyDumping th e Cargo BoxWARNINGOperating the vehicle while the cargo box is raised could result insevere injury. The box could

48OPERATIONDriving SafelyTowing LoadsWARNINGTowing improperly can alter vehicle handling and may cause lossof control or brake instability, which can

49OPERATIONDriving SafelyParking the RANGERWARNINGA rolling vehicle can cause property damage and serious injury.Always engage the park brake after st

50OPERATIONDifferential Lock (4X4)The 4X4 rear axle is equipped with a lockabledifferential that allows the operator t o choosebetween an open differe

151OPERATIONAll Wheel Drive (AWD)The illuminated amber AWD switch (1)indicates that the vehicle is in AWD.When the AWD switch is on, the frontwheels w

52EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with U

53MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition

54MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartMaintenance Chart Key" Perform these procedures more frequently for vehicles subjected to

55MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Inter

56MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"EEngine b

3TABLE O F CONTENTSVEHICLE IDENTIFICATION NUMBERS 4...SAFETY 5...FEATURES AND CONTROLS 23...OPERATION

57MAINTENANCE AND LUBRICATIO NPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)JEFuel system 1

58MAINTENANCE AND LUBRICATIO NLubrication RecommendationsCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart

59MAINTENANCE AND LUBRICATIO NLubrication Recommendations(1)(3)6X64X46X66X66X6(2)4X46X6

60MAINTENANCE AND LUBRICATIO NEngine OilAlways check and change the engine oil at the intervals outlined in thePeriodic Maintenance Chart beginning on

61MAINTENANCE AND LUBRICATIO NEngine OilAlways check and change the oil at the intervals outlined in thePeriodic Maintenance Chart beginning on page 5

62MAINTENANCE AND LUBRICATIO NEngine OilOil an d Filter ChangeCAUTIONHot oil can cause serious burns to skin. Do not allow hot oil tocome into contact

63MAINTENANCE AND LUBRICATIO NEngine OilOil an d Filter Change12. Remove the dipstick and fill the sump with two quarts (1.9 l) ofrecommended oil.13.

164MAINTENANCE AND LUBRICATIO NGearcasesTransmission (Main Gearcase)Always check and change the transmission oil at the intervals outlinedin the Perio

65MAINTENANCE AND LUBRICATIO NGearcasesTransmission (Main Gearcase)Oil ChangeThe drain plug (2) is located on thebottom of the transmission. Access th

1266MAINTENANCE AND LUBRICATIO NGearcasesFront GearcaseAlways check and change the front gearcase oil at the intervalsoutlined in the Periodic Mainten

4VEHICLE IDENTIFICATION NUMBERSRecord your vehicle’s identification numbers and key number in thespaces provided. Remove the spare key and store it in

67MAINTENANCE AND LUBRICATIO NGearcasesMiddle Gearcase (RANGER 6X6)Always check and change the middle gearcase oil at the intervalsoutlined in the Per

12126X64X468MAINTENANCE AND LUBRICATIO NGearcasesRear GearcaseAlways check and change the rear gearcase oil at the intervals outlinedin the Periodic M

69MAINTENANCE AND LUBRICATIO NGearcasesRear GearcaseOil Change1. Remove the fill plug.2. Place a drain pan under the drain plug (2). Remove the drain

70MAINTENANCE AND LUBRICATIO NSpark PlugsCAUTIONUsing non-recommended spark plugs can result in serious enginedamage. Always use Polaris-recommended s

71MAINTENANCE AND LUBRICATIO NSpark Plugs2. Wet FouledThe wet fouled insulator tip is black. A damp oil film covers the firingend. There may be a carb

72MAINTENANCE AND LUBRICATIO NCooling SystemOperationThe engine coolant level is controlled or maintai ned by the recoverysystem. The recovery system

73MAINTENANCE AND LUBRICATIO NCooling SystemRadiator and Cooling FanAlways check and clean the screen and radiator fins at the intervalsoutlined in th

174MAINTENANCE AND LUBRICATIO NCooling SystemRadiator Coolant LevelAlways check and change the coolant at the intervals outlined in thePeriodic Mainte

75MAINTENANCE AND LUBRICATIO NPolaris Variable Transmission (PVT) SystemBelt slip is responsible for creating excessive heat that destroys belts,wears

76MAINTENANCE AND LUBRICATIO NPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modi

5SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin severe injury or death.A Polaris RANGER is not a toy

77MAINTENANCE AND LUBRICATIO NPVT SystemPVT DryingThere may be some instances when water is accidently ingested intothe PVT system. Use the following

178MAINTENANCE AND LUBRICATIO NFilter SystemsAir FilterAlways change the air filter at the intervals outlined in the PeriodicMaintenance Chart beginni

79MAINTENANCE AND LUBRICATIO NSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious in

1280MAINTENANCE AND LUBRICATIO NThrottle SystemWARNINGFailure to check or maintain proper operation of the throttlesystem can result in an accident an

81MAINTENANCE AND LUBRICATIO NThrottle SystemThrottle Freeplay Adjustment1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosenthe ad

182MAINTENANCE AND LUBRICATIO NBrakesThe front and rear brakes are hydraulic disc type brakes and areactivated by the brake pedal. See page 32.Brake F

83MAINTENANCE AND LUBRICATIO NBrakesBrake Inspection5. Check the brake system for fluidleaks.6. Check the brake pedal for excessivetravel or a spongy

84MAINTENANCE AND LUBRICATIO NSteering Wheel InspectionCheck the steering wheel for specified freeplay and smooth operationat the intervals outlined i

85MAINTENANCE AND LUBRICATIO NSeat BeltsInspect all three seat belts for proper operation before each use of thevehicle.1. Push the latch plate into t

86MAINTENANCE AND LUBRICATIO NTiresWARNINGOperating your vehicle with worn tires will increase the possibilityof skidding, loss of control and an acci

6SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your RANGER. Your safety is involved when thesewords

87MAINTENANCE AND LUBRICATIO NTiresWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in serious

188MAINTENANCE AND LUBRICATIO NLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causin

189MAINTENANCE AND LUBRICATIO NLightsHeadlight Beam Adjustment1. Place the vehicle on a level surface with the headlightapproximately 25 ft. (7.6 m) f

90MAINTENANCE AND LUBRICATIO NLightsIndicator L amp Replacement1. Lift the hood.2. Reach in behind the consolepanel and lift the release (1) tounplug

91MAINTENANCE AND LUBRICATIO NVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the vehicle is not thoroughly

92MAINTENANCE AND LUBRICATIO NBatteryKeep the battery terminals and connections free of corrosion. Ifcleaning is necessary, remove the corrosion with

93MAINTENANCE AND LUBRICATIO NBatteryReplenishing Battery Fluid (Conventional Battery)A poorly maintained battery will deterioraterapidly. Check the b

94MAINTENANCE AND LUBRICATIO NBatteryBattery Installation1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstr

95MAINTENANCE AND LUBRICATIO NCleaning and StorageSee page 99 for the part numbers of Polaris products.Cleaning the RANGERKeeping your RANGER clean wi

96MAINTENANCE AND LUBRICATIO NCleaning and StorageStorage TipsCAUTIONStarting the engine during the storage period will disturb theprotective film cre