2007 Polaris Ranger 500 4x4 Owners Manual

2007 Polaris Ranger 500 4x4 Manual

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  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 1
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 2
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 3
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 4
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 5
    reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2007 RANGER 2X4/RANGER 4X4 Owner's Manual P/N 9920634 2
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 6
    TABLE OF CONTENTS Vehicle Identification Numbers...4 Safety ...5 Features and Controls ...22 Operation ...32 Emission Control Systems ...51 Maintenance ...52 Specifications ...102 Polaris Products...106 Troubleshooting ...107 Warranty ...111 Maintenance Log ...121 Index ...123 3
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 7
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 8
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 9
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 10
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 11
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 12
    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 to the vehicle. NOTE: A note will alert you to important information or instructions. 9
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 13
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 14
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 15
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 16
    Operator Safety WARNING SAFETY 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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 17
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 18
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 19
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 20
    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. SAFETY WARNING POTENTIAL HAZARD Operating on frozen bodies of water
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 21
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 22
    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. Always maintain proper tire pressure as described on the decal and in the Owner
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 23
    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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 24
    Fuel Safety WARNING SAFETY 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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 25
    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 102. Cab Frame (if Equipped) Console Steering Wheel Hip Bar Storage Box Seat (
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 26
    Component Locations FEATURES AND CONTROLS Headlights Radiator (if equipped) Hood Hold-Down Strap Front Bumper/Brush Guard 23
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 27
    FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Tailgate Taillights Air Box Receiver Hitch CV Boot/Rear Caliper Muffler (Spark Arrestor) 24
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 28
    Component Locations Indicator Lights FEATURES AND CONTROLS The indicator light panel is located on the console. See page 28. Brakes Reverse Gear Low Gear (if equipped) High Temperature Neutral Gear High Gear Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 29
    FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into 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/Fuel Gauge The
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 30
    the latch plate into the buckle until it clicks. 3. Release the strap, it will self tighten. Seat Belt 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 center. 27
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 31
    FEATURES AND CONTROLS Console Cup Holder Indicator Lights Gear Selector (Shifter) Light Switch AWD/Differential Switch Cup Holder Storage Box Ignition Switch Storage Tray 12V Accessory Outlet Choke Knob Storage Compartment (with lid) 28
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 32
    is moving. NOTE: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 33
    the park brake, apply the brakes, then push the park brake pedal down firmly and fully with your foot. Park Brake Release Always apply the service brakes before releasing the park brake. To release the park brake, pull the park brake release handle. Make sure the park brake pedal is functioning
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 34
    switch to engage All Wheel Drive (AWD). See page 50 for AWD operating instructions. Move the rocker switch to the center position to lock the differential and two wheel drive (2WD). See page 49 for Differential Lock operating instructions. Press the bottom of the switch to unlock the differential and
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 35
    OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 36
    Pre-Ride Inspection WARNING OPERATION If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Brake system/pedal travel Brake fluid Front suspension Rear suspension
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 37
    OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Sit in the driver's seat and fasten the seat belt. 2. Engage the park brake. 3. Shift the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 38
    Starting the Engine OPERATION 8. After the engine starts, push the choke knob in half way. 9. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. 10. Push the choke knob in. CAUTION Operating the vehicle immediately after starting could cause engine
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 39
    Procedure 1. Sit in the driver's seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the service brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the park brake. 5. Keeping both hands
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 40
    Driving Safely OPERATION Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 41
    . Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at high
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 42
    Driving Safely OPERATION WARNING Driving on a Sidehill (Sidehilling) Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 43
    to the pedal repeatedly until braking action is normal. NOTE: After running your vehicle in water, it's critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 52. Give special attention to engine oil, transmission oil, front and rear gearcases, and
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 44
    Driving Safely OPERATION Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you'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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 45
    injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual. Always back slowly. 42
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 46
    Driving Safely OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 47
    with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 48
    Driving Safely Hauling Cargo OPERATION The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model RANGER 4X4 RANGER 2X4 Maximum Capacities (Level Ground)
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 49
    OPERATION Driving Safely Dumping the Cargo Box 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 will also catch the rear of a raised box, damaging the vehicle and
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 50
    Driving Safely Towing Loads OPERATION WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than the recommended vertical tongue weight on
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 51
    OPERATION Driving Safely Parking the Vehicle WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. 2. 3. 4. Stop the vehicle on a level surface. Turn the engine off. Engage the park brake. Remove the ignition switch
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 52
    in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed. See page 50 for AWD operating instructions. 2WD/Rear Differential Locked Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). Locking the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 53
    causes increased steering effort and some vehicle speed restriction. If the front gearcase remains locked after following these instructions, return the vehicle to your dealer for service. 1. Stop the vehicle. 2. Operate in reverse for at least 10 feet. 3. Stop completely. 4. Shift into low gear and
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 54
    Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 55
    riding conditions and an average vehicle speed of approximately ten (10) miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed, heavy
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 56
    X Perform these operations more often for vehicles subjected 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 result in component failure and lead
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 57
    MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval ( X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 58
    ) X Engine oil change E X Oil filter change E X Oil tank vent hose E E Q Valve clearance X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 59
    Spark arrestor Idle speed Q Toe adjustment Q Auxiliary brake (if X equipped) Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 60
    Lubrication Recommendations MAINTENANCE Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 61
    MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 62
    Engine Oil MAINTENANCE Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil tank is located under the seat. 1. Position the vehicle on a level
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 63
    MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 64
    Engine Oil MAINTENANCE Oil and Filter Change 10. Reattach the oil line. 11. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 13. Lubricate the gasket
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 65
    MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 66
    Gearcases Gearcase Main Gearcase (Transmission) (4X4) Main Gearcase (Transmission) (2X4) Front Gearcase (4X4) Rear Gearcase (2X4, 4X4) MAINTENANCE Lubricant Premium AGL Synthetic Gearcase Lube Premium AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Premium ATV Angle Drive Fluid Gearcase
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 67
    MAINTENANCE Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Drain the oil. 4.
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 68
    fill plug. Check the oil level. 3. Add the recommended oil as needed. 4. Reinstall the fill plug. Torque to specification. Fill Plug Oil Change 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's Drain Plug side. 3. Remove the fill plug. 4. Place a drain pan
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 69
    MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 106 for
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 70
    Spark Plugs CAUTION MAINTENANCE Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model RANGER 4X4 RANGER 2X4 Electrode Gap .036" (.9 mm) New Plug
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 71
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 72
    Cooling System Operation MAINTENANCE The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 73
    MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 74
    Cooling System MAINTENANCE Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 75
    (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 76
    when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Loosen the bottom screws seconds. 4. Allow the engine RPM to settle to idle speed. Apply the service brakes. Release the park brake and shift the transmission to the lowest available range
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 77
    . 9. Reconnect the fuel pump wires. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT follow the procedure on
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 78
    edges of the filter before installing. 5. Inspect the air box for oil or water deposits. If present, drain them into a suitable container. NOTE: Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. Fuel Filter Your
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 79
    engine. Secure the clamps. CAUTION Operation of the vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service. 76
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 80
    Carburetor MAINTENANCE The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/200. If the engine idle speed is not satisfactory, and all other conditions
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 81
    MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 82
    operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misadjustment, it will cause a delay
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 83
    original position. Cylinder Head/Cylinder Base Fastener Torque Have your dealer check the cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. 80
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 84
    Brakes Brake Fluid MAINTENANCE The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30. Inspect the brake system rouBrake Fluid tinely. Inspect the level of the Reservoir brake fluid before each operation. Change the brake fluid
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 85
    MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when worn
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 86
    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 page 52. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. 3. There
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 87
    MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red button in the middle of
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 88
    ) or less. 1/8" (3 mm) Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Nut Type Lug Nut Location Front and Rear Nut Torque 90 ft. lbs. (122 Nm) 2-Piece Flange Nut Spindle Nut Hub Retaining Nuts
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 89
    tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 90
    dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement 1. Open the hood. 2. Unplug the headlamp from the wiring harness. Be
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 91
    MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3.
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 92
    Lights MAINTENANCE Brake Lights When the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel. If the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 93
    MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 94
    Battery WARNING MAINTENANCE Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 95
    has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 94 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 96
    Battery MAINTENANCE Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 97
    charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 98
    Battery MAINTENANCE Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 99
    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 100
    the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 101
    and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 102
    See page 96. Stabilize the Fuel 1. Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 103
    MAINTENANCE Storage Tips Cleaning and Storage Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. 2. Reinstall the spark plug. Torque to specification. See page 67. 3. Apply dielectric grease to the inside of the spark plug cap. Reinstall the cap.
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 104
    Removal from Storage MAINTENANCE 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 105
    SPECIFICATIONS RANGER 2X4 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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 106
    SPECIFICATIONS RANGER 2X4 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake,
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 107
    SPECIFICATIONS RANGER 4X4 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
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 108
    SPECIFICATIONS RANGER 4X4 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake,
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 109
    POLARIS PRODUCTS Part Number 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2872889 2871326 2870652 2872189 2870990 2872893 2871956 2871076 Description Engine Lubricant Fogging
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 110
    in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range during loading. Use low range. See warnings on page 38. Drive at a higher speed or use low range more frequently
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 111
    TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Tripped circuit breaker Solution Recharge the battery to 12.8 VDC
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 112
    Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range TROUBLESHOOTING Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 113
    TROUBLESHOOTING Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Fouled or defective spark plugs Worn
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 114
    and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 115
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests 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 dealer require any additional assistance they will
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 116
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 117
    WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 118
    maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you retain all receipts covering your LSI engine to a dealer authorized by POLARIS as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 119
    WARRANTY California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with the applicable regulations of the
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 120
    California Emission Control Warranty Statement WARRANTY Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 121
    such as changing, adding or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable to follow the maintenance and operating instructions specified in the 2005 and later Owner's Manual including: (a) Improper or inadequate
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 122
    , such as dirty or wet conditions. Q Due to the nature of these adjustments, it is recommended that an authorized Polaris dealer perform service. Do not attempt to perform this work unless you are familiar with mechanical repair. Maintenance Schedule Item Maintenance Interval (whichever comes first
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 123
    . These replacement parts will be provided at no charge if the part is still under warranty. How to File a Warranty Claim/Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 124
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 121
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 125
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 122
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 126
    INDEX A Adding Coolant...69 Adjustment Headlight Beam ...88 Park Brake...82 Rear Spring ...83 Rear Suspension ...83 Throttle Freeplay...80 Age Restrictions ...8 Air Filter ...75 Air Filter Cleaning ...75 All Wheel Drive ...50 All Wheel Drive Lock Switch ...31 Arrestor, Spark, Warning ...78 Auxiliary
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 127
    INDEX E Electromagnetic Interference...51 Emission Control, Crankcase...51 Emission Control, Exhaust ...51 Emission Control, Noise ...51 Emissions Limited Warranty ...114 Engine Fogging ...100 Engine Idle RPM Adjustment ...77 Engine Oil ...58-62 Engine Starting ...34-35 Engine Stopping...35
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 128
    INDEX M Main Gearcase Lubrication ...63 Oil Change ...64 Oil Check ...63 Maintenance Log ...121-122 Maintenance, Periodic ...52-56 Modifications ...13 P Polishing the Vehicle ...97 Premium 4 Synthetic Oil ...58 Pre-Ride Inspection ...33 Pressure, Tire ...5 Public Lands ...51 PVT Drying ...73 PVT
  • 2007 Polaris Ranger 500 4x4 | Owners Manual - Page 129
    INDEX S Storage ...96-100 Storage and Inspection...99 Storage and Lubrication...99 Storage Area ...100 Battery ...93 Covers ...100 Fluid Levels ...99 Oil and Filter ...99 Removal From ...101 Suspension Adjustment, Rear ...83 Switch, AWD/Differential Lock ...31 Switch, Ignition ...31 Switch, Light
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