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!

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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

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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

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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.
+

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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