Polaris Ranger 4x4 500 EFI 2007 Owner'S Manual Download Page 2

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Summary of Contents for Ranger 4x4 500 EFI 2007

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Page 3: ...ns 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 th...

Page 4: ...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 abou...

Page 5: ...quality 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 ar...

Page 6: ...icle Identification Numbers 4 Safety 5 Features and Controls 22 Operation 32 Emission Control Systems 53 Maintenance 54 Specifications 106 Polaris Products 108 Troubleshooting 109 Warranty 113 Mainten...

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 VI...

Page 8: ...y passengers in cargo box Maximum 2X4 Box Load 850 lbs 386 kg Maximum 4X4 Box Load 1000 lbs 455 kg Maximum 6X6 Box Load 1200 lbs 545 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control...

Page 9: ...or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 Age 16 Warning Operating this vehicle if you are under the age...

Page 10: ...Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt the cab frame is not designed or intended to provide roll over protection Vehicle rollover could cause seve...

Page 11: ...ng 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 desig...

Page 12: ...eir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death o...

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 vehicle Never operate at excessive speeds Alw...

Page 14: ...id 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 att...

Page 15: ...ry 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 28 Always...

Page 16: ...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 your...

Page 17: ...Never apply engine power Apply the brakes gradually When fully stopped engage the park brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage...

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...

Page 19: ...equires 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 prohi...

Page 20: ...e 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...

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 W...

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 veh...

Page 23: ...ent have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems CAUTION Exhaust system components are very hot duri...

Page 24: ...ted 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 cl...

Page 25: ...re equipped with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 106 Cab Frame if Equipped Console Hip Bar Cargo Box...

Page 26: ...receiver hitch 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 pag...

Page 27: ...onal accessories or lights The connections are behind the console under the hood Fuel Gauge Hour Meter Lighted bars in the upper display indicate fuel level Hours of engine operation since manufacture...

Page 28: ...he 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 transmiss...

Page 29: ...ept Acc 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released WARN...

Page 30: ...Off 1WD Turf Mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 52 for AWD operating instructions Move the rocker switch to the center position to lock the differential an...

Page 31: ...e switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Inspect and adjust park brake cable tension after the first 25 hours of operation and...

Page 32: ...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 square red button in the buckle s cente...

Page 33: ...the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle...

Page 34: ...he desired position Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressu...

Page 35: ...result in more efficient performance and longer life for the engine Perform the following pro cedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage clo...

Page 36: ...vels controls and areas outlined on the daily pre ride inspection checklist See page 34 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours 8 Inspect an...

Page 37: ...ure free operation 86 Tires Inspect condition and pressure 5 88 Wheels fasteners Inspect ensure fastener tightness 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper lev...

Page 38: ...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...

Page 39: ...elease the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Apply the brakes 4 Engage the park brake WARNING A rolling vehicle can cause serious injury Always engage the...

Page 40: ...famil iar 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 Failure to allow for increased brakin...

Page 41: ...oundings 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...

Page 42: ...wheel in the direction of the skid 4 Drive with AWD engaged if equipped to assist in controlling the vehicle NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels ar...

Page 43: ...raking 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...

Page 44: ...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 Alway...

Page 45: ...utlined in the Periodic Maintenance Chart beginning on page 54 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings WARNING The large tires on your RA...

Page 46: ...u 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 obsta...

Page 47: ...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 seriou...

Page 48: ...downhill side WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake when stopping the engine Always block the downhill side of the wheels if leaving the v...

Page 49: ...ich 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...

Page 50: ...he warning labels Never exceed the following capacities Model Maximum Capacities Level Ground Cargo Box RANGER 4X4 500 EFI 1500 lbs 681 kg 1000 lbs 454 kg WARNING Driving with passengers in the cargo...

Page 51: ...ecurely 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 w...

Page 52: ...an 10 mph 16 km h when towing See page 46 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 specificat...

Page 53: ...rolling vehicle can cause property damage and serious injury Always engage the park brake when stopping the engine WARNING Gasoline is extremely flammable and can be explosive under certain condition...

Page 54: ...e in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Diffe...

Page 55: ...sengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching...

Page 56: ...c Violations are subject to monetary penalties Fed eral regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase sys...

Page 57: ...vice 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 ap...

Page 58: ...ected 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 r...

Page 59: ...ers 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 Cool...

Page 60: ...ication 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...

Page 61: ...ses 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 12 M Inspect replace as needed Q Ignition timing 100 H 12 M Inspect X W...

Page 62: ...lubricated at the general lubrication interval Item Lube Method Engine Oil Polaris Premium 4 Synthetic 0W40 See page 61 Brake Fluid DOT 4 See page 84 Main Gearcase Oil Transmission Premium AGL Synthet...

Page 63: ...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 u...

Page 64: ...0 seconds Stop the engine 3 Remove the seat See page 30 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick Screw it in completely NOTE The dipstick must be screwed in comple...

Page 65: ...and oil tank should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 8 Disconnect the lower oil delivery hose and remove the screen fitting from the...

Page 66: ...then turn and additional 1 2 turn 15 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surface...

Page 67: ...ly 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If...

Page 68: ...products Oil Check The fill plug is located at the rear of the vehicle 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 Rei...

Page 69: ...Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 5 After the oil has drained completely install a new sealing washer NOTE Refer to the Gearcase Specifications Chart...

Page 70: ...n the right side of the front gearcase 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...

Page 71: ...the oil level even with the bottom thread of the fill plug hole 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 th...

Page 72: ...plug for correct color See page 70 NOTICE Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning...

Page 73: ...justments 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 cau...

Page 74: ...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 dra...

Page 75: ...e coolant level 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...

Page 76: ...he hood 2 Slowly remove the radiator 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 bee...

Page 77: ...system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and...

Page 78: ...he engine Engage the park brake Shift the transmission to neutral 3 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...

Page 79: ...the spark plugs Turn the engine over several times using the electric start 5 Dry the spark plugs and reinstall or replace with new plugs 6 Attempt to start the engine If necessary repeat the drying p...

Page 80: ...adjustable and should be adjusted for both the operator and passengers before driving Although having the belt at 30 is typical for many people it will not accommodate all body sizes and shapes Make s...

Page 81: ...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 presen...

Page 82: ...for debris Blow gently through the filter in the direction of the arrow to check for clog ging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall...

Page 83: ...stem temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front...

Page 84: ...elled cover or plug the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 5 If particles are still suspected to be in the muffler elevate the re...

Page 85: ...he brakes Engage the park brake Shift the transmission to neutral 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up...

Page 86: ...nline 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 82 NOTE While adjusting lig...

Page 87: ...surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper...

Page 88: ...ar damage and looseness 4 Inspect the brake disc spline and pad wear surface for excessive wear 5 Change pads when worn to 3 64 1 mm Park Brake Inspection 1 Apply the brakes 2 Pull the park brake leve...

Page 89: ...tor This will inactivate the limiting function Reconnect the connector as soon as possible and adjust the park brake cable to proper tension 1 Position the vehicle on a level surface 2 Shift the trans...

Page 90: ...eposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft lbs 40 Nm Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adj...

Page 91: ...n 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 ma...

Page 92: ...the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and washers Remove the wheel WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling whi...

Page 93: ...Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion 4 Attach the wheel nuts and washers...

Page 94: ...ring 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 assemb...

Page 95: ...ne Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider...

Page 96: ...ach in behind the console panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembl...

Page 97: ...towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery Conventional Battery WARNING Battery electrolyte is poisono...

Page 98: ...ventional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the ba...

Page 99: ...vent tube sealed bat teries do not 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...

Page 100: ...ery 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 th...

Page 101: ...the 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...

Page 102: ...tandard 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 mont...

Page 103: ...th 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 o...

Page 104: ...ntact 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...

Page 105: ...nt 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 periodi...

Page 106: ...o run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 62 Air Filter Air Box Inspect and clean or replace...

Page 107: ...led with the pre measured amount of oil NOTE Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be a...

Page 108: ...zed Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 54 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply th...

Page 109: ...6 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 12 in 30 5 cm Min Turning Radius 158 in 401 cm Towing Capacity 1500 lbs 681 kg Max Cargo Box Load 1000 lbs 454 kg...

Page 110: ...ion Reverse 7 91 1 Gear Reduction High 3 85 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 70 1 Tire Size Front 25 x 10 12 Tire Size Rear 25 x 11 12 Tire Pressure Front 8 12 psi 69 KPa Tire Pressure R...

Page 111: ...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...

Page 112: ...mission 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...

Page 113: ...Solution Out of fuel Refuel 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...

Page 114: ...spark plug gap or 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 bat...

Page 115: ...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 volt...

Page 116: ...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...

Page 117: ...sts 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 deale...

Page 118: ...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...

Page 119: ...r replacement of 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 SHAL...

Page 120: ...117 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...118 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...119 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 123: ...ts 109 C Capacity Weight 47 Cargo 46 47 Cargo Box Dumping 48 Changing Coolant 71 Changing Gears 25 Changing Oil Engine 62 Front Gearcase 67 Rear Gearcase 68 Transmission Main Gearcase 66 Chart Gearcas...

Page 124: ...2 Filter Cleaning Air 78 Filter Cleaning Fuel 78 Filter Systems 78 79 Filter Air 78 Filter Breather 79 Filter Fuel 78 Fluid Levels During Storage 104 Fluid Battery 97 Fluid Brake 84 Fogging the Engine...

Page 125: ...rcase 67 Main Gearcase 65 Rear Gearcase 68 Transmission 65 O Oil Pump Priming 64 Oil Engine 60 64 Oil Synthetic 60 Operation on Public Lands 53 Operation Cooling System 71 Operation Transmission 74 Op...

Page 126: ...tches AWD Switch 27 Differential Lock Switch 27 Ignition Switch 26 Light Switch 27 Synthetic Oil 60 T Throttle Freeplay Adjustment 83 Throttle Freeplay Inspection 82 Throttle Freeplay 82 Throttle Peda...

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Polaris Ranger 4x4 500 EFI 2007, Owner'S Manual

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