Polaris 4X4 700 EFI, 6X6 700 EFI User Manual

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Polaris 4X4 700 EFI, 6X6 700 EFI User Manual

WARNING

Read, understand, and follow all of the instructions and safety precautions 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.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

Snowmobiles

All-terrain vehicles (ATVs)

RANGER utility vehicles

Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For 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 interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

1

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. 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 prohibited.

Printed in U.S.A.

2007 RANGER 4X4 700 EFI/RANGER 6X6 700 EFI Owner’s Manual P/N 9920636

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TABLE OF CONTENTS

Vehicle 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

3

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Key

Number

####

VIN

Engine Serial Number

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

4

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Container/Passenger/Tire Pressure Warning

WARNING

 

Remove flammable material

+

containers from box before filling.

 

• Passengers can be thrown off. This can cause 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 MACHINE, DRIVER AND CARGO:

RANGER 2X4 and 4X4 is 2750 LBS. RANGER 6X6 is 2900 LBS.

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box.

Read Owner's Manual for more detailed loading information.

5

SAFETY

Safety Decals and Locations

Cab Frame/Seat Belt

Warning

Clutch Cover

Warning

Clutch Cover Warning

WARNING

NO STEP

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

Do not modify 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.

6

SAFETY

Safety Decals and Locations

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.

Discretionary Warning

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

Operate on public roads. A collision can occur with a another vehicle.

Carry more than two passengers, or passengers under age five.

Use ALCOHOL or DRUGS before or while operating this vehicle.

Operate at speeds too fast for your skills or the conditions.

Operate this vehicle on HILLS steeper than 15 degrees 15°. To prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

Shift

Caution

Discretionary

Warning

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 supply increased braking, but should be used as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.

THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating the vehicle.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger in this vehicle.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning 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 vehicle are thoroughly inspected at specific intervals.

8

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert 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 will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

Read this manual and all labels carefully. Follow the operating procedures described.

Never allow anyone without a valid driver's license to operate this vehicle.

Minimum age recommendation for passengers is five years old. Passengers under five years of age require special restraints which are not available with this vehicle. Driver and passenger should wear their seat belts at all times.

Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels.

To reduce tipover risk, be especially careful when encountering obstacles and slopes and when braking on hills or during turns.

This vehicle is for off road use only. Never operate on public roads. Always avoid paved surfaces.

Helmets are recommended whenever 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. Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

Never attempt jumps or other stunts.

Always inspect your vehicle each time you use it to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation.

Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

Never operate on excessively rough, slippery or loose terrain.

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SAFETY

Operator Safety

Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident.

Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel 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 careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on page 5.

11

SAFETY

Operator Safety

Never modify this vehicle through improper installation or use of accessories.

Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury 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. Gasoline is extremely flammable. See page 21 for fuel safety warnings.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800- 342-3764.

12

SAFETY

Operator Safety

WARNING

Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

Do not make any modifications to your RANGER.

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris RANGER is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain 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.

13

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards while climbing a hill

WHAT CAN HAPPEN Vehicle overturn

HOW TO AVOID THE HAZARD

Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes.

Engage the park brake after fully stopped.

If you begin rolling backwards:

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, 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 affect handling and control of the vehicle, and may cause the vehicle to go out of control.

Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.

14

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle without proper instruction WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations 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 gravel.

In many states it's illegal to operate vehicles of this type on public streets, roads and highways.

15

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle after consuming alcohol or drugs

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.

Could result in an accident. HOW TO AVOID THE HAZARD

Driving a RANGER 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 HAZARD

Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

16

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN

Loss of control, accident and/or vehicle 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.

17

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN

Accident, equipment damage HOW TO AVOID THE HAZARD

Always inspect your RANGER before each use to make sure it's in safe operating condition.

Always 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 operating the vehicle. You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react.

18

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN

Serious injury or death (the child or others) HOW TO AVOID THE HAZARD

Only persons with a valid driver's license should operate a Polaris RANGER.

Even though a child may be within the age group for which some vehicles 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 the Owner's Manual for this vehicle. See page 5.

Always maintain proper tire pressure as described on the decal and in the Owner's Manual. See page 5.

19

SAFETY

Operator Safety

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, 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 traveling through tall grass, especially dry grass.

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SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

Always stop the engine when refueling.

Always refuel outdoors or in a well ventilated 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 of consciousness and death in a short time.

21

FEATURES AND CONTROLS

Component Locations

Some Polaris vehicles are equipped 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)

Steering

 

Wheel

Hip Bar

Console

 

Storage Box

Seat

(under driver seat)

 

Battery

Cargo Box

(under hood)

Seat Belts

Fuel Tank Cap

22

FEATURES AND CONTROLS

Component Locations

Headlights

 

Radiator

 

(if equipped)

Hood

 

Hold-Down

 

Strap

Front Bumper/Brush Guard

 

23

FEATURES AND CONTROLS

Component Locations

Tailgate

Latch Release

Taillights

Taillights

Tailgate

 

Air Box

CV Boot/Rear Caliper

Receiver Hitch

Muffler

 

(Spark Arrestor)

Trailer Hitch Bracket

This vehicle is equipped with a 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 pages 50-53.

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FEATURES AND CONTROLS

Component Locations

Instrument Cluster

Your RANGER is equipped with an instrument cluster that senses vehicle speed from the right 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.

Park Brake

Indicator Speedometer

Speedometer

Needle

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists.

25

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis.

1. Gear Indicator - This

3

4

5

6

7

indicator displays gear

 

 

 

 

 

shifter position.

 

 

 

 

8

H = High Gear

 

 

 

 

L = Low Gear

 

 

 

 

 

N = Neutral

 

 

 

 

 

R = Reverse Gear

2

 

 

 

 

2. AWD Indicator - This

 

 

 

 

indicator illuminates

 

 

 

 

 

when the AWD switch

 

 

 

 

 

is in the AWD posi-

 

1

 

 

 

tion.

 

 

 

 

 

3.Engine Hour Display Indicator

4.Service Interval/Diagnostic 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 electrical 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 segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

8.Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

26

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode button located under the speedometer to toggle through the mode options. See page 34.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip 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 decimal 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 fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page 28.

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