Owners Manual
Page 5
... U.S.A. 2007 RANGER 4X4 500 EFI Owner's Manual P/N 9920635 2 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 is expressly prohibited. Any reprinting or reuse of Polaris Industries Inc. Printed in part, is based on the latest product information at the time...
... U.S.A. 2007 RANGER 4X4 500 EFI Owner's Manual P/N 9920635 2 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 is expressly prohibited. Any reprinting or reuse of Polaris Industries Inc. Printed in part, is based on the latest product information at the time...
Owners Manual
Page 10
... OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. FOLLOW ALL INSTRUCTIONS AND WARNINGS. NEVER: • Operate on hills and rough terrain and in SEVERE INJURY or DEATH. Discretionary • Operate this vehicle on hilly terrain, use can result in turns. • Wear eye protection. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES. Shift...
... OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. FOLLOW ALL INSTRUCTIONS AND WARNINGS. NEVER: • Operate on hills and rough terrain and in SEVERE INJURY or DEATH. Discretionary • Operate this vehicle on hilly terrain, use can result in turns. • Wear eye protection. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES. Shift...
Owners Manual
Page 16
... modifications to your RANGER. Modifications may change the handling characteristics of bodily injury. Failure of critical machine components may result from operation with their function and effect on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any modifications have been made to ) mowers, blades, tires, sprayers, or large racks, may also create...
... modifications to your RANGER. Modifications may change the handling characteristics of bodily injury. Failure of critical machine components may result from operation with their function and effect on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any modifications have been made to ) mowers, blades, tires, sprayers, or large racks, may also create...
Owners Manual
Page 28
... 44-47. The connections are behind the console, under the hood. Component Locations Indicator Lights FEATURES AND CONTROLS The indicator light panel is equipped with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on the back that may be used to power an auxiliary light or other optional accessories or lights. Trailer towing equipment is not supplied with a receiver...
... 44-47. The connections are behind the console, under the hood. Component Locations Indicator Lights FEATURES AND CONTROLS The indicator light panel is equipped with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on the back that may be used to power an auxiliary light or other optional accessories or lights. Trailer towing equipment is not supplied with a receiver...
Owners Manual
Page 34
... switch to the center position to lock the differential and operate in the ON/RUN position to engage All Wheel Drive (AWD). Turn the key to the START position to the ON position when released. This mode of operation is well suited to unauthorized use Light Switch The ignition switch key must be in two wheel drive (2WD). Switches Light Switch AWD/ Differential Switch Ignition Switch FEATURES AND CONTROLS High Beam Low Beam OFF AWD 2WD OFF Ignition Switch The ignition switch is off. Electrical...
... switch to the center position to lock the differential and operate in the ON/RUN position to engage All Wheel Drive (AWD). Turn the key to the START position to the ON position when released. This mode of operation is well suited to unauthorized use Light Switch The ignition switch key must be in two wheel drive (2WD). Switches Light Switch AWD/ Differential Switch Ignition Switch FEATURES AND CONTROLS High Beam Low Beam OFF AWD 2WD OFF Ignition Switch The ignition switch is off. Electrical...
Owners Manual
Page 35
... not operate at first. See page 33. 6. Careful treatment of a new engine will result in period, change both the oil and the filter at full throttle or high speeds for extended periods during the first three hours of gasoline. Drive slowly at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on page 21. 2. During the break-in more...
... not operate at first. See page 33. 6. Careful treatment of a new engine will result in period, change both the oil and the filter at full throttle or high speeds for extended periods during the first three hours of gasoline. Drive slowly at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on page 21. 2. During the break-in more...
Owners Manual
Page 48
Model RANGER 4X4 500 EFI Maximum Capacities (Level Ground) 1500 lbs. (681 kg) Cargo Box 1000 lbs. (454 kg) WARNING Driving with passengers in the cargo box can result in the cab with seat belts fastened securely. 45 Never exceed the following capacities. Never allow passengers to carry or tow specific capacities. Passengers must always ride in severe injury or death. Driving Safely Hauling Cargo OPERATION The RANGER has been designed to ride in the cargo box. Always read and understand the load distribution warnings listed on the warning labels.
Model RANGER 4X4 500 EFI Maximum Capacities (Level Ground) 1500 lbs. (681 kg) Cargo Box 1000 lbs. (454 kg) WARNING Driving with passengers in the cargo box can result in the cab with seat belts fastened securely. 45 Never exceed the following capacities. Never allow passengers to carry or tow specific capacities. Passengers must always ride in severe injury or death. Driving Safely Hauling Cargo OPERATION The RANGER has been designed to ride in the cargo box. Always read and understand the load distribution warnings listed on the warning labels.
Owners Manual
Page 50
... tow a trailer on the towing bracket. Model RANGER 4X4 500 EFI Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 47 Driving Safely Towing Loads OPERATION WARNING Towing improperly can alter vehicle handling and...
... tow a trailer on the towing bracket. Model RANGER 4X4 500 EFI Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 47 Driving Safely Towing Loads OPERATION WARNING Towing improperly can alter vehicle handling and...
Owners Manual
Page 53
... the length of time the vehicle may cause severe drive shaft and clutch damage. Stop the vehicle. 2. OPERATION All Wheel Drive (AWD) The illuminated amber AWD AWD Switch switch indicates that the vehicle is turned off while the front gearcase is no limit to AWD while the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 50 Disengaging AWD Under certain conditions, it will automatically disengage. This condition causes increased steering...
... the length of time the vehicle may cause severe drive shaft and clutch damage. Stop the vehicle. 2. OPERATION All Wheel Drive (AWD) The illuminated amber AWD AWD Switch switch indicates that the vehicle is turned off while the front gearcase is no limit to AWD while the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 50 Disengaging AWD Under certain conditions, it will automatically disengage. This condition causes increased steering...
Owners Manual
Page 57
... Monthly Monthly Monthly X Front suspension X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment E tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 54 replace as needed Inspect periodically Check terminals; clean often; change coolant every 2 years Check...
... Monthly Monthly Monthly X Front suspension X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment E tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 54 replace as needed Inspect periodically Check terminals; clean often; change coolant every 2 years Check...
Owners Manual
Page 59
clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; clean; adjust as needed Adjust as needed Inspect Inspect for vehicles subjected to water, mud, etc. Inspect; E Emission-Related Service. replace worn parts Inspect; re Replace yearly Inspect; Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Q Auxiliary brake (if X equipped) Headlight aim X Perform these services. 56 replace as needed Inspect periodically; replace as needed Change every two years Clean out Adjust...
clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; clean; adjust as needed Adjust as needed Inspect Inspect for vehicles subjected to water, mud, etc. Inspect; E Emission-Related Service. replace worn parts Inspect; re Replace yearly Inspect; Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Q Auxiliary brake (if X equipped) Headlight aim X Perform these services. 56 replace as needed Inspect periodically; replace as needed Change every two years Clean out Adjust...
Owners Manual
Page 70
... 100. WARNING A hot exhaust system and engine can result in serious engine damage. Wear protective gloves when removing a spark plug for correct color. Spark Plugs CAUTION MAINTENANCE Using non-recommended spark plugs can cause serious burns. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is indicative of engine operation. Immediately check the spark plug for inspection. 67 Spark Plug Gap/Torque Model RANGER 4X4 500 EFI Electrode Gap...
... 100. WARNING A hot exhaust system and engine can result in serious engine damage. Wear protective gloves when removing a spark plug for correct color. Spark Plugs CAUTION MAINTENANCE Using non-recommended spark plugs can cause serious burns. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is indicative of engine operation. Immediately check the spark plug for inspection. 67 Spark Plug Gap/Torque Model RANGER 4X4 500 EFI Electrode Gap...
Owners Manual
Page 84
Lightly turn the steering wheel left and right. 3. Suspension Adjustment The 4X4 rear suspension may be 0.8"-1.0" (20-25 mm) of freeplay. 4. Reinstall the shock mounting bolts. Position the vehicle on page 52. 1. Torque to the outside mounting holes. 3. Steering Wheel Inspection MAINTENANCE Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on a level surface. 2. Outside Mounting Holes Inside Mounting Holes Cam...
Lightly turn the steering wheel left and right. 3. Suspension Adjustment The 4X4 rear suspension may be 0.8"-1.0" (20-25 mm) of freeplay. 4. Reinstall the shock mounting bolts. Position the vehicle on page 52. 1. Torque to the outside mounting holes. 3. Steering Wheel Inspection MAINTENANCE Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on a level surface. 2. Outside Mounting Holes Inside Mounting Holes Cam...
Owners Manual
Page 89
... 2. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Measure the distance from a wall. 2. Apply the brakes. Observe the headlight aim. Adjustment Screw View of driver's headlight with the headlight approximately 25 ft. (7.6 m) from the floor to adjust the beam. 7. Turn the adjustment screw to the center of a rider on a level surface with hood lifted. 86 Start the engine. Place the vehicle on the seat while performing this...
... 2. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Measure the distance from a wall. 2. Apply the brakes. Observe the headlight aim. Adjustment Screw View of driver's headlight with the headlight approximately 25 ft. (7.6 m) from the floor to adjust the beam. 7. Turn the adjustment screw to the center of a rider on a level surface with hood lifted. 86 Start the engine. Place the vehicle on the seat while performing this...
Owners Manual
Page 103
SPECIFICATIONS RANGER 4X4 500 EFI Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing Spark Plug Front Suspension Rear Suspension 2700 lbs. (1226 kg) 1185 lbs. (537 kg) 113 in. (282 cm) 60 in. (152.4 cm) 58 in. (147.3 cm) 75 in. (190...
SPECIFICATIONS RANGER 4X4 500 EFI Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing Spark Plug Front Suspension Rear Suspension 2700 lbs. (1226 kg) 1185 lbs. (537 kg) 113 in. (282 cm) 60 in. (152.4 cm) 58 in. (147.3 cm) 75 in. (190...
Owners Manual
Page 104
Front: Drive Ratio - Front Tire Pressure - High Drive Ratio - Final Tire Size - SPECIFICATIONS RANGER 4X4 500 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Reverse Gear Reduction - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light Dry Sump 0W/40 PVT Single Lever (console) 8.71:1 5.9:1 3.83:1 3.83:1 3.70:1 25 x 10 - 12 25 x 11 - 12 8-12 psi 8-12 psi Foot Activated, 4 wheel hydraulic disc Foot activated, mechanical 2 dual beam, 35W, quartz/halogen 2 single...
Front: Drive Ratio - Front Tire Pressure - High Drive Ratio - Final Tire Size - SPECIFICATIONS RANGER 4X4 500 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Reverse Gear Reduction - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light Dry Sump 0W/40 PVT Single Lever (console) 8.71:1 5.9:1 3.83:1 3.83:1 3.70:1 25 x 10 - 12 25 x 11 - 12 8-12 psi 8-12 psi Foot Activated, 4 wheel hydraulic disc Foot activated, mechanical 2 dual beam, 35W, quartz/halogen 2 single...
Owners Manual
Page 115
... a problem exists. What is Covered Under This Warranty Repair and/or replacement of that a warranted emission-related part is delivered, to the original retail purchaser and ends two years after that POLARIS may cause it to fail to conform with the applicable regulations of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). Any warranted part which the LSI engine...
... a problem exists. What is Covered Under This Warranty Repair and/or replacement of that a warranted emission-related part is delivered, to the original retail purchaser and ends two years after that POLARIS may cause it to fail to conform with the applicable regulations of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). Any warranted part which the LSI engine...
Owners Manual
Page 121
...Headlight Beam ...86 Park Brake ...80 Rear Spring ...81 Rear Suspension ...81 Throttle Freeplay ...78 Age Restrictions...8 Air Filter ...74 Air Filter Cleaning...74 All Wheel Drive...50 All Wheel Drive Lock Switch ...31 Arrestor, Spark, Warning...76 Auxiliary Outlet ...25 AWD ...50 AWD/Differential Lock Switch...31 Axle Nut Torque ...83 C Changing Oil Engine ...60 Front Gearcase...65 Rear Gearcase ...66 Transmission/Main Gearcase . . 64 Chart, Gearcase Specifications ...63 Chart, Periodic Maintenance ...52-56 Checking Oil Level Engine ...59 Front Gearcase...65 Rear Gearcase ...66 Transmission...
...Headlight Beam ...86 Park Brake ...80 Rear Spring ...81 Rear Suspension ...81 Throttle Freeplay ...78 Age Restrictions...8 Air Filter ...74 Air Filter Cleaning...74 All Wheel Drive...50 All Wheel Drive Lock Switch ...31 Arrestor, Spark, Warning...76 Auxiliary Outlet ...25 AWD ...50 AWD/Differential Lock Switch...31 Axle Nut Torque ...83 C Changing Oil Engine ...60 Front Gearcase...65 Rear Gearcase ...66 Transmission/Main Gearcase . . 64 Chart, Gearcase Specifications ...63 Chart, Periodic Maintenance ...52-56 Checking Oil Level Engine ...59 Front Gearcase...65 Rear Gearcase ...66 Transmission...
Owners Manual
Page 122
......86 Headlight Lamp Replacement ...85 Hitch Weight...47 I Idle Speed ...Ignition Switch ...Indicator Light Replacement ...Indicator Lights...Inspection Axle Nuts ...Brakes ...Park Brake ...Pre-Ride ...Seat Belts ...Steering Wheel ...Throttle Freeplay ...Wheel Nuts ...Installation, Battery...Installation, Wheels ...Interference, Electromagnetic...78 31 87 25 83 80 80 33 82 81 77 83 90 84 51 F Fan, Cooling ...70 Fastener Torque, Cylinder Head/Base ...78 Filling the Battery ...91 Filter Care During Storage ...97 Filter Change...60 Filter Cleaning, Air ...74 Filter Cleaning, Fuel ...74 Filter...
......86 Headlight Lamp Replacement ...85 Hitch Weight...47 I Idle Speed ...Ignition Switch ...Indicator Light Replacement ...Indicator Lights...Inspection Axle Nuts ...Brakes ...Park Brake ...Pre-Ride ...Seat Belts ...Steering Wheel ...Throttle Freeplay ...Wheel Nuts ...Installation, Battery...Installation, Wheels ...Interference, Electromagnetic...78 31 87 25 83 80 80 33 82 81 77 83 90 84 51 F Fan, Cooling ...70 Fastener Torque, Cylinder Head/Base ...78 Filling the Battery ...91 Filter Care During Storage ...97 Filter Change...60 Filter Cleaning, Air ...74 Filter Cleaning, Fuel ...74 Filter...
Owners Manual
Page 123
...66 Oil Change...66 Oil Check...66 Rear Spring Adjustment ...81 Rear Suspension Adjustment...81 Release, Park Brake...30 Removal, Battery ...89 Removal, Seat ...26 Removal, Wheels...84 Removing the Vehicle from Storage . 99 Replacement, Headlight Lamp ...85 Reverse ...42 RPM, Idle, Throttle Body ...78 S Safety Decals ...5-7 Safety Symbols ...9 Seat Belt Inspection ...82 Seat Belts ...27, 82 Seat Removal...26 Selector, Gear ...29 Severe Use Definition ...52 Shifter ...29 Shifting Gears ...29 Signal Words ...9 Spark Arrestor Warning...76 Spark Arrestor, Cleaning ...76 Spark Plug Condition ...68...
...66 Oil Change...66 Oil Check...66 Rear Spring Adjustment ...81 Rear Suspension Adjustment...81 Release, Park Brake...30 Removal, Battery ...89 Removal, Seat ...26 Removal, Wheels...84 Removing the Vehicle from Storage . 99 Replacement, Headlight Lamp ...85 Reverse ...42 RPM, Idle, Throttle Body ...78 S Safety Decals ...5-7 Safety Symbols ...9 Seat Belt Inspection ...82 Seat Belts ...27, 82 Seat Removal...26 Selector, Gear ...29 Severe Use Definition ...52 Shifter ...29 Shifting Gears ...29 Signal Words ...9 Spark Arrestor Warning...76 Spark Arrestor, Cleaning ...76 Spark Plug Condition ...68...