Polaris 4X4 700 EFI Owner'S Manual Download

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114

TROUBLESHOOTING

Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Loose battery connections

Check all connections and tighten

Loose solenoid connections

Check all connections and tighten

Loose electronic control box connections

Inspect, clean, reinstall connectors

Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel filter

Inspect and clean or replace

Water is present in fuel

Drain the fuel system and refuel

Old or non-recommended fuel

Replace with fresh recommended fuel

Fouled or defective spark plugs

Inspect plugs and replace if necessary

No spark to spark plug

Inspect plugs and replace if necessary

Water or fuel in crankcase

Immediately see your Polaris dealer

Low battery voltage

Recharge the battery to 12.8 VDC

Mechanical failure

See your dealer

Possible Cause

Solution

Weak spark from spark plug

Inspect, clean and/or replace spark plugs

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Old or non-recommended fuel

Replace with fresh recommended fuel

Incorrectly installed spark plug wires

See your dealer

Incorrect ignition timing

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Check all connections and tighten

Water present in fuel

Replace with fresh recommended fuel

Summary of Contents for 4X4 700 EFI

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Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly p...

Page 6: ...hicle Identification Numbers 4 Safety 5 Features and Controls 22 Operation 38 Emission Control Systems 57 Maintenance 58 Specifications 108 Polaris Products 112 Troubleshooting 113 Warranty 117 Maintenance Log 126 Index 128 ...

Page 7: ... your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number ____________________________________________________...

Page 8: ...e serious injury or death Never carry passengers in cargo box Maximum 2X4 Box Load 850 lbs Maximum 4X4 Box Load 1000 lbs Maximum 6X6 Box Load 1200 lbs IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI RANGER 2X4 and 4X4 FRONT 10 REAR 10 RANGER 6X6 FRONT 10 CENTER 10 REAR 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MA...

Page 9: ...y engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Cab Frame Seat Belt Warning WARNING VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection ALWAYS WEAR YOUR SEAT BELT for maximum protection Cab Frame Seat Belt Warning Clutch Cover Warning ...

Page 10: ... hilly terrain use throttle and brakes gradually ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supp...

Page 11: ...ing the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals WARNING Failure to follow the warnings contained in this manual can result in severe injury ...

Page 12: ...rt symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note ...

Page 13: ...ever driving this vehicle in an aggressive manner Eye protection is recommended at all times Never consume alcohol or drugs before or while operating this vehi cle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experi ence Never attempt jumps or other stunts Always inspect your vehicle each time you use it to make sure...

Page 14: ...el downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be care...

Page 15: ...njury in case of a sudden stop or collision Always keep arms and legs inside the cab frame while the vehicle is in motion Always engage the park brake before getting out of the vehicle See page 36 Always apply the service brakes before releasing the park brake Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gas o...

Page 16: ...n accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle WARNING Make sure your RANGER is in excellent operating condition at all times We strongly recommend that the operator check all safety components b...

Page 17: ...In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affe...

Page 18: ... and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway including dirt or gr...

Page 19: ...requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE H...

Page 20: ...le overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water ...

Page 21: ... follow the inspection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when op...

Page 22: ...icles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in th...

Page 23: ... have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when ...

Page 24: ...ated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss ...

Page 25: ...with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 108 Cab Frame if Equipped Console Steering Wheel Hip Bar Fuel Tank Cap Seat Belts Cargo Box Battery under hood Seat Storage Box under driver seat ...

Page 26: ...23 FEATURES AND CONTROLS Component Locations Headlights Hood Hold Down Strap Front Bumper Brush Guard Radiator if equipped ...

Page 27: ... bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 50 53 Tailgate Latch Release Taillights Air Box Receiver Hitch CV Boot Rear Caliper Muffler Spark Arrestor Taillights Tailgate ...

Page 28: ...t front wheel The instrument cluster measures distance in miles as well as time hours of operation and engine RPM Refer to page 34 for the location of the instrument cluster NOTE In addition to showing vehicle speed the speedometer needle flashes when a low fuel condition exists Rider Information Center Speedometer Speedometer Needle Park Brake Indicator ...

Page 29: ...c Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge The...

Page 30: ...rip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctu...

Page 31: ... button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Press and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour...

Page 32: ...ur dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 se...

Page 33: ...the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle...

Page 34: ...riptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Engage the parking brake 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END di...

Page 35: ...cuit to Battery 53 Rear Differential Open Load RANGER 4X4 only 53 Rear Differential Short Circuit to Ground RANGER 4X4 only 53 Rear Differential Short Circuit to Battery RANGER 4X4 only 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Batte...

Page 36: ...belts for the operator and passenger To wear the seat belt properly follow this procedure 1 Place the belt across your lap as low on your hips as possible Make sure that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tightened manually by pulling on the strap 4 To release the seat belt press the s...

Page 37: ...the console under the hood Mode Button The yellow button located directly under the speedometer is used to tog gle through mode options available such as odometer trip meter hour meter tachometer and clock See page 27 for operation of the modes Cup Holder Light Switch Cup Holder Storage Compartment with lid AWD Differential Switch if equipped 12V Accessory Outlet Mode Button Storage Tray Ignition ...

Page 38: ...e lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving NOTE Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift...

Page 39: ...rottle pedal freeplay See page 86 for throttle pedal adjustment procedures Park Brake Pedal Engage the park brake when parking the vehicle to help prevent the vehicle from rolling To engage the park brake apply the brakes then push the park brake pedal down firmly and fully with your foot Park Brake Release Always apply the service brakes before releasing the park brake To release the park brake p...

Page 40: ...to lock the differential and operate in two wheel drive 2WD See page 55 for Differ ential Lock operating instructions Press the bottom of the switch to unlock the differ ential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed WARNING Leaving the keys in the ignition can lead to unauthorized use ...

Page 41: ...perating range 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 39 6 Pull only light loads 7 During the break in period change both the oil and the...

Page 42: ...sure free operation 89 Tires Inspect condition and pressure 5 91 Wheels fasteners Inspect ensure fastener tightness 91 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 66 Coolant level Ensure proper level 78 79 Coolant hoses Inspect for leaks Throttle Ensure proper operation 85 Indicator lights switches Ensure operation 37 Air filter pre filter Inspect clean...

Page 43: ...6 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an...

Page 44: ...l you re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in acc...

Page 45: ...our surroundings and determine your path of travel 4 Release the park brake 5 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces NOTE Low gear is the primary range for operating the RANGER High gear is intended for use on hard packed...

Page 46: ...teering wheel in the direction of the skid 4 Drive with AWD engaged if equipped to assist in controlling the vehicle CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss...

Page 47: ...a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never op...

Page 48: ...the side of a hill when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15 maximum WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always opera...

Page 49: ... vices outlined in the Periodic Maintenance Chart beginning on page 58 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RAN...

Page 50: ...errain you re traveling on Watch for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain ...

Page 51: ...d backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly ...

Page 52: ...ownhill side WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead Operating the vehicle while the park brake is engaged could cause loss of control and result in serious injury or death Always disen...

Page 53: ...tions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a load...

Page 54: ...bels Never exceed the following capacities Model Maximum Capacities Level Ground Cargo Box RANGER 4X4 EFI 1500 lbs 681 kg 1000 lbs 454 kg RANGER 6X6 EFI 1750 lbs 794 kg 1250 lbs 567 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely ...

Page 55: ...curely to latch WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position WARNING If the weight distrib...

Page 56: ...g See page 50 Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 108 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Model Total...

Page 57: ...rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot li...

Page 58: ...el Drive AWD Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate indepen dently 1WD This mode of opera tion is well suited to turf driving or whenever aggressive traction is not required CAUTION Damage to the differential can occur if it is enga...

Page 59: ...n the differential is locked and the vehicle is in two wheel drive See page 55 The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unnecessarily This condition caus...

Page 60: ...3 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are control...

Page 61: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style hi...

Page 62: ...jected to severe use E Emission Control System Service 4 Cycle California Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 63: ... Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X E Air box sediment tube Daily Drain deposits when visible Coolant if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly In...

Page 64: ...eral lubrication 50 H 3 M Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M Inspect lubricate adjust Q Steering 50H 6 M Lubricate X Front Suspension 50 H 6 M Lubricate X Rear Suspension 50 H 6 M Lubricate Q E Throttle cable ETC switch 50 H 6 M Inspect adjust lubricate replace if necessary E Throttle body air intake ducts flange 50 H 6 M Inspect duct for proper seal ing air leaks Driv...

Page 65: ...ng Hoses 100 H 12 M Inspect for leaks X Engine mounts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect X E Spark plug 100 H 12M Inspect replace as needed Q Ignition timing 100 H 12 M Inspect X Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M Inspect clean replace worn parts Q Front ...

Page 66: ...L Synthetic Gearcase Lube See page 69 Front Gearcase Oil Premium Demand Drive Hub Fluid See page 71 Middle Gearcase Oil 6X6 only Premium ATV Angle Drive Fluid See page 72 Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 73 Prop Shaft U joints Polaris Premium U Joint Lube Locate fittings and grease See page 64 Front Prop Shaft Yoke Polaris Premium U Joint Lube Locate fittings and grease 3 p...

Page 67: ...64 MAINTENANCE Lubrication Recommendations 4X4 6X6 Swing Arm Bushings 6X6 Prop Shaft U Joints 4X4 6X6 6X6 Ball Joint 6X6 ...

Page 68: ... F Its exceptional frictional prop erties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem...

Page 69: ...o remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the ...

Page 70: ... plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 20 ft lbs 27 Nm 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 9 Using a clean dry cloth clean the filter sealing surface on the crank case 10 Lubricate the o ring on the new filte...

Page 71: ...d filter and oil properly Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase Transmission Premium AGL Synthetic Gearcase Lube 15 2 oz 450 ml 14 ft lbs 19 4 Nm 14 ft lbs 19 4 Nm Front Gearcase Premium Demand Drive Hub Fluid 5 oz 150 ml 8 10 ft lbs 11 13 6 Nm 11 ft lbs 15 Nm Middle Gearcase 6X6 Premium ATV Angle Drive Fluid 6 75 oz 200...

Page 72: ...fill plug hole Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 112 for the part numbers of Polaris products The fill plug is located at the rear of the vehicle Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug To...

Page 73: ...pan under the drain plug Remove the drain plug Drain the oil Dispose of used oil properly 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 4 After the oil has drained com pletely install a new sealing washer 5 Reinstall the drain plug Torque to specification 6 Add the recommended oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification 8...

Page 74: ...ight side of the front gear case Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to spec ification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom rig...

Page 75: ...rs of Polaris products The middle gearcase fill plug is located on the side of the gearcase Oil Check 1 Position the vehicle on a level sur face 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Remove the fill plug 2 Remove the drain plug from the bottom of the gearcase Drain the oil into a drain pan Disca...

Page 76: ...ar gearcase Oil Check 4X4 Maintain the oil level 3 4 19 mm below the bottom thread of the fill plug hole Use a light colored non absorbent measuring instrument such as a white cable tie to mea sure the depth 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Check 6X6 The eas...

Page 77: ...2 Place a drain pan under 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 Torque to specifica tion 5 Add the recommended oil 6 Reinstall the fill plug Torque to specification 7 Check for leaks ...

Page 78: ...e page 76 CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 108 Model Electrode Gap New Plug Torque Used Plug Torque RANGER 4X4 EFI 035 9 mm 18 ft lbs 24 Nm 18 ft lbs 24 Nm RANGER 6X6 EFI 035 9 mm 18 ft lbs 24 Nm 18 ft lbs 24 Nm WARNING A hot exhaust system and engine can ca...

Page 79: ...djustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjust ments Spark Plug Removal and Replacement 1 Remove the seat to access the engine compartment 2 R...

Page 80: ... as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible a...

Page 81: ... between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle is located in front of the right front wheel 1 Position the vehicle on a level surface 2 View the coolant level in the overflow bottle 3 If the coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the lid and use a funnel to add coolant through the fill...

Page 82: ... Slowly remove the radi ator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected NOTE Use of a non standard pressure cap will not allow the recovery system to ...

Page 83: ...er clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High ...

Page 84: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owne...

Page 85: ... the engine 5 Engage the park brake 6 Shift the transmission to neutral 7 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 8 Allow the engine RPM to settle to idle speed Apply the service brakes Release the park brake and shift the transmission to the low est available range 9 Test for belt ...

Page 86: ... main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container NOTE Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods Fuel Filter Your Pola...

Page 87: ...mission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine Allow the arrestor to cool 7 Reinstall the arrestor plugs and remove the outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the s...

Page 88: ...ark brake Shift the transmission to neutral 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the thro...

Page 89: ...Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 85 NOTE While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it ...

Page 90: ...ke fluid level at the reservoir under the hood The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING After opening a bottle of brake fluid always discard any unused portion Never store or u...

Page 91: ... Change pads when worn to 3 64 1 mm Park Brake Inspection 1 Slowly push the park brake pedal down with your foot 2 After 8 to 12 clicks of pedal travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjust the park brake Park Brake Adjustment 1 Position the vehicle on a level surface 2 Shift the transmission to neutral 3 Loosen or tighten the nuts on t...

Page 92: ...ugh or catchy have the steering system inspected by an autho rized Polaris dealer Suspension Adjustment 4X4 The 4X4 rear suspension may be adjusted to provide a stiffer suspension if necessary 1 Remove the top shock mounting bolts from the inside mounting holes 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft lbs 40 Nm Rear Spring Adjustmen...

Page 93: ...adjustable and should be adjusted for both the operator and passengers before driv ing Although having the belt at 30 is typical for many peo ple it will not accommodate all body sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 2 Reposition both the buckle and retractor Tighten the bolts NOTE The center belt does no...

Page 94: ...an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Nut T...

Page 95: ...the correct posi tion on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward for ward rotation 4 Attach the wheel nuts and washers and finger tighten 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts to specification See page 91 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can res...

Page 96: ...g 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality...

Page 97: ...lude the weight of a rider on the seat while performing this step 5 If the headlight needs adjustment open the hood NOTE The lights are part of the hood assembly 6 Turn the adjustment screw to adjust the beam 7 Close the hood Repeat steps 4 6 until the beam is properly adjusted Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 ...

Page 98: ...e spark plugs 6 Turn the engine over several times using the electric start 7 Dry the spark plugs and reinstall or replace with new plugs NOTE Attempt to start the engine If necessary repeat the drying procedure 8 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 82 for...

Page 99: ...ry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of m...

Page 100: ...onal battery side ways which could spill elec trolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last CAUTION If electrolyte spills immediately wash it off with a solution of ...

Page 101: ...have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are proper...

Page 102: ...ttery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 112 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the b...

Page 103: ... sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fu...

Page 104: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 105: ...ith a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish CAUTION High water pressure may damage c...

Page 106: ...ontact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishi...

Page 107: ...ent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pr...

Page 108: ...ilter Change the oil and filter See page 67 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter See page 83 Clean the air box Drain the sediment tube Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 58 Front and rear gearcase fluid Transmission fluid Brake fluid change every two years and any ti...

Page 109: ...cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 76 4 Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil 6 If Polaris fuel system additi...

Page 110: ...n authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Stop the engine 2 Remove the key to prevent loss during transporting 3 Place the transmission in gear 4 Engage the park brake 5 Secure the fuel cap oil cap and seat 6 Always tie the frame of the RANG...

Page 111: ...all Height 75 in 190 5 cm Wheelbase 76 in 193 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 132 in 335 3 cm Engine 4 valve 4 stroke twin cylinder with counter bal ance Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 W 3000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System Electronic Fuel Injection Igni...

Page 112: ...ar Reduction Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 26 x 8 12 Tire Size Rear 26 x 11 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single b...

Page 113: ...rgo Box L x W x H 58 x 48 x 10 in 147 x 122 x 25 4 cm Ground Clearance 7 2 in 18 cm Min Turning Radius 180 in 457 2 cm Engine 4 valve 4 stroke twin cylinder with counter bal ance Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 W 3000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug Gap RC7YC 035 in 0 9 mm Fro...

Page 114: ...Gear Reduction Reverse 5 9 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 25 x 10 12 Tire Size Center Rear 25 x 11 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Ligh...

Page 115: ...b Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease NyogelTM 2872073 Cha...

Page 116: ...nsmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle ...

Page 117: ...ended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spa...

Page 118: ...r heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Possibl...

Page 119: ... Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clea...

Page 120: ... Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactur...

Page 121: ...ests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state...

Page 122: ...o an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination coun...

Page 123: ...f any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE A...

Page 124: ...olaris must warrant the emission control system on your LSI engine for the period of time described below provided there has been no abuse neglect or improper mainte nance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLA...

Page 125: ... California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below Warranty Period This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period...

Page 126: ... Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines...

Page 127: ...engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2005 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and mainte nance se...

Page 128: ...lated part is found to be defective during the warranty period you must notify the Polaris War ranty Department at 1 763 417 8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km X E Air filter pre filter Daily Inspect clean often X E Air box sediment tube Daily Drain depos...

Page 129: ...126 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 130: ...127 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 131: ...pacity Weight 51 Cargo 50 51 Cargo Box Dumping 52 C Changing Coolant 77 Changing Gears 35 Changing Oil Front Gearcase 71 Middle Gearcase 72 Rear Gearcase 74 Transmission Main Gearcase 70 Chart Gearcase Specifications 68 Chart Periodic Maintenance 58 62 Checking Oil Front Gearcase 71 Middle Gearcase 72 Transmission Main Gearcase 69 Chrome Wheel Care 104 Cleaning and Storage 102 106 Cleaning Air Fil...

Page 132: ...ing Storage 105 Fluid Battery 99 Fluid Brake 87 Fogging the Engine 106 Fouled Plugs 76 Freeplay Adjustment Throttle 86 Freeplay Steering Wheel 89 Front Gearcase Lubrication 71 Oil Change 71 Oil Check 71 F Fuel Cap 33 Fuel Filter 83 Fuel Safety 21 Fuel Stabilizer 105 Fuel Tank Filler Cap 33 G Gap Spark Plug 75 Gear Circuit Diagnostics 29 Gear Selector 35 Gearcase Lubrication 69 Specification Chart ...

Page 133: ...e 70 Middle Gearcase 72 Rear Gearcase 74 Transmission 70 O Oil Check Engine 66 Front Gearcase 71 Main Gearcase 69 Middle Gearcase 72 Rear Gearcase 73 Transmission 69 Oil Engine 65 68 Operation on Public Lands 57 Operation Cooling System 77 Operation Transmission 80 Operator Safety 8 20 P Park Brake Adjustment 88 Inspection 88 Pedal 36 Release 36 Parking on an Incline 49 Parking the Vehicle 54 Peri...

Page 134: ...the Engine 41 Storage 102 106 Storage and Inspection 105 Storage and Lubrication 105 Storage Area 106 Storage Battery 99 Covers 106 Fluid Levels 105 Oil and Filter 105 Removal From 107 S Suspension Adjustment Rear 89 Switches AWD Switch 37 Differential Lock Switch 37 Ignition 37 Light 37 T Tachometer 27 29 Throttle Freeplay Adjustment 86 Throttle Freeplay Inspection 85 Throttle Pedal 36 Throttle S...

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