Polaris Ranger 4x4 500 EFI 2007 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.

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide 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 recre-
ational vehicles manufactured in the world today. Many years of experi-
ence 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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries 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 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 prohibited.
Printed in U.S.A.
2007 RANGER 4X4 500 EFI Owner’s Manual
P/N 9920635

3
TABLE OF CONTENTS
Vehicle Identification Numbers. . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emission Control Systems . . . . . . . . . . . . . . . 51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 100
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 116
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

4
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.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number ____________________________________________________________
Engine Serial Number
VIN
Key
Number
####

5
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.
+

6
SAFETY
Safety Decals and Locations
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.
Cab Frame/Seat Belt
Warning
Clutch Cover
Warning

7
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:
• 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.
Shift
Caution
Discretionary
Warning

8
SAFETY
Operator Safety
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 informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
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 vehi-
cle are thoroughly inspected at specific intervals.
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.

9
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 sym-
bols 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.

10
SAFETY
Operator Safety
• 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.
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.

11
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 trav-
eling 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 skid-
ding 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 stop-
ping 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 and in the
specifications section beginning on page 100.

12
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 fol-
low 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 30.
• Always apply the 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-
oline is extremely flammable. See page 21 for fuel safety warnings.
• Always remove the ignition key when the vehicle is not in use to pre-
vent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-
342-3764.

13
SAFETY
Operator Safety
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 vehi-
cle 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.
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.

14
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.

15
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.

16
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.

17
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.