Polaris Ranger 6X6 700 EFI 2006, Owner'S Manual

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Page 3: ...ns 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 th...

Page 4: ...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 abou...

Page 5: ...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 ar...

Page 6: ...icle Identification Numbers 4 Safety 5 Features and Controls 22 Operation 40 Emission Control Systems 58 Maintenance 59 Specifications 106 Polaris Products 108 Troubleshooting 109 Warranty 113 Mainten...

Page 7: ...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 VI...

Page 8: ...y passengers in cargo box Maximum 2X4 Box Load 850 lbs 386 kg Maximum 4X4 Box Load 1000 lbs 455 kg Maximum 6X6 Box Load 1200 lbs 545 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control...

Page 9: ...or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 Cab Frame Seat Belt Warning WARNING VEHICLE ROLLOVER could cau...

Page 10: ...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 RIDIN...

Page 11: ...ng 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 desig...

Page 12: ...t 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 s...

Page 13: ...g 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 drivin...

Page 14: ...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 ge...

Page 15: ...hicle 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 Al...

Page 16: ...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 your...

Page 17: ...the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed WARNING POTENTIAL HAZARD Operating this vehicle on paved surfac...

Page 18: ...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...

Page 19: ...equires 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 prohi...

Page 20: ...e 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...

Page 21: ...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 W...

Page 22: ...cles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident WARNING POTENTIAL HAZARD Operating this vehi...

Page 23: ...have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Exhaust system components are very hot during a...

Page 24: ...ted area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or cl...

Page 25: ...ed with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 106 Cab Frame if Equipped Console Steering Wheel Hip Bar Fuel...

Page 26: ...23 FEATURES AND CONTROLS Component Locations Headlights Hood Hold Down Strap Front Bumper Brush Guard Radiator if equipped...

Page 27: ...bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 52 55 Tailga...

Page 28: ...front wheel The instrument cluster measures distance in miles as well as time hours of operation and engine RPM Refer to page 34 for the location of the instrument cluster NOTE In addition to showing...

Page 29: ...Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle a...

Page 30: ...ip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point bu...

Page 31: ...as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Press and hold the...

Page 32: ...r dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purpos...

Page 33: ...he button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and...

Page 34: ...Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Apply the brakes Engage the parking brake 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the...

Page 35: ...2 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short...

Page 36: ...low on your hips as possible Make sure that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tighten...

Page 37: ...are behind the console under the hood Mode Button The yellow button located directly under the speedometer is used to tog gle through mode options available such as odometer trip meter hour meter tac...

Page 38: ...ining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Seat Removal Pull up on the front of the seat and slide it to...

Page 39: ...tle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the en...

Page 40: ...s moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100...

Page 41: ...off except Acc 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when releas...

Page 42: ...heel Drive AWD and Off 2WD Press the top of the rocker switch to engage All Wheel Drive AWD See page 57 for AWD operating instructions Light Switch The ignition switch key must be in the ON RUN positi...

Page 43: ...Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 41 6 Pull only light...

Page 44: ...ure free operation 87 Tires Inspect condition and pressure 5 89 Wheels fasteners Inspect ensure fastener tightness 89 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper lev...

Page 45: ...If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 4 and 5 until the engine starts 6 Vary the engine RPM slightly with the throttle to aid...

Page 46: ...you re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking WARNING A rolling vehicle can cause pro...

Page 47: ...4 Release the park brake 5 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 6 Drive slowly Practice maneuvering and usi...

Page 48: ...the steering wheel in the direction of the skid 4 Drive with AWD engaged to assist in controlling the vehicle CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels...

Page 49: ...hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hi...

Page 50: ...he side of a hill when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15 maximum WARNING Traveling downhill improperly could cause loss of control or vehicle overtur...

Page 51: ...vices outlined in the Periodic Maintenance Chart beginning on page 59 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings WARNING The large tires on...

Page 52: ...rrain 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 a...

Page 53: ...backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING Failure to use caution when operating in reverse can result i...

Page 54: ...n the downhill side WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Always block the downhill side of the wheels if leavin...

Page 55: ...ing or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of...

Page 56: ...essories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities RANGER 6X6 700 EFI Maximum Capacities Level Ground Cargo Box 1750 lb...

Page 57: ...down securely to latch 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...

Page 58: ...n 10 mph 16 km h when towing See page 52 Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specificati...

Page 59: ...RNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine WARNING Gasoline is extremely flammable and can be explosive under certain c...

Page 60: ...switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction Disengaging AWD Under certain conditions it may be possible for the front gearcase to...

Page 61: ...1 c Violations are subject to monetary penalties Fed eral regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase s...

Page 62: ...vice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of ap...

Page 63: ...ntenance Interval whichever comes first Remarks Hours Calendar Miles Km Q Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 41 X Front suspension Pre Ride X Rear suspension...

Page 64: ...m a break in oil change at one month Park brake cable tension 25 H 1 M Check tension adjust X General lubrication 50 H 3 M Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M Inspect lubri...

Page 65: ...faces X Cooling Hoses 100 H 12 M Inspect for leaks X Engine mounts 100 H 12 M Inspect Exhaust muffler pipe 100 H 12 M Inspect X E Spark plug 100 H 12M Inspect replace as needed Q Ignition timing 100 H...

Page 66: ...c Gearcase Lube See page 68 Front Gearcase Oil Premium Demand Drive Hub Fluid See page 70 Middle Gearcase Oil Premium ATV Angle Drive Fluid See page 71 Rear Gearcase Oil Premium ATV Angle Drive Fluid...

Page 67: ...4 cycle oil or a similar oil See page 108 for the part num bers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil...

Page 68: ...cloth 3 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 4 Remove the dipstick and check the oil leve...

Page 69: ...plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 20 ft lbs 27 Nm 8 Place shop towels beneath the oil...

Page 70: ...level to the upper mark on the dipstick 18 Dispose of used filter and oil properly Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase...

Page 71: ...ill plug hole Refer to the Gearcase Specifications Chart on page 67 for recommended lubricants capacities and torque specifications See page 108 for the part numbers of Polaris products The fill plug...

Page 72: ...an under the drain plug Remove the drain plug Drain the oil Dispose of used oil properly 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 4 After the oil has drai...

Page 73: ...ght side of the front gear case Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to s...

Page 74: ...of Polaris products The middle gearcase fill plug is located on the side of the gearcase Oil Check 1 Position the vehicle on a level sur face 2 Remove the fill plug Check the oil level 3 Add the recom...

Page 75: ...se fill plug is on the driver s side of the rear gearcase Oil Check The easiest way to check for ade quate oil in the 6X6 is to drain and refill the gearcase to capacity see page 67 Perform the oil ch...

Page 76: ...ck the spark plug for correct color See page 74 CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications sec...

Page 77: ...justments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General cau...

Page 78: ...as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely dra...

Page 79: ...between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle is located in front of the right front wheel 1 Position the vehicle on a level surface 2 View the coolant...

Page 80: ...Slowly remove the radi ator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained...

Page 81: ...r clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc When To Use Low Range and High Range Condition Range to Use Operati...

Page 82: ...tional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this...

Page 83: ...the engine 5 Engage the park brake 6 Shift the transmission to neutral 7 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide...

Page 84: ...main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If presen...

Page 85: ...e transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine Allow the arrestor to cool 7 Reinstall the arrestor plugs and rem...

Page 86: ...he brakes Engage the park brake Shift the transmission to neutral 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up...

Page 87: ...queeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3...

Page 88: ...e fluid level at the reservoir under the hood The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper M...

Page 89: ...r damage and looseness 4 Inspect the brake disc spline and pad wear surface for excessive wear 5 Change pads when worn to 3 64 1 mm Park Brake Inspection 1 Apply the brakes 2 Pull the park brake lever...

Page 90: ...ible and adjust the park brake cable to proper tension 1 Position the vehicle on a level surface 2 Shift the transmission to neutral 3 Loosen or tighten the nuts on the lever end of the park brake cab...

Page 91: ...djustable and should be adjusted for both the operator and passengers before driv ing Although having the belt at 30 is typical for many peo ple it will not accommodate all body sizes and shapes Make...

Page 92: ...n accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires ma...

Page 93: ...ace the wheel in the correct posi tion on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward for ward rotation 5 Attach the wheel nuts and washers...

Page 94: ...3 Turn the lamp counter clockwise to remove it 4 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly W...

Page 95: ...e weight of a rider on the seat while performing this step 5 If the headlight needs adjust ment open the hood The lights are part of the hood assembly 6 Turn the adjustment screw to adjust the beam 7...

Page 96: ...spark plugs 6 Turn the engine over several times using the electric start 7 Dry the spark plugs and reinstall or replace with new plugs NOTE Attempt to start the engine If necessary repeat the drying...

Page 97: ...y off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery WARNING Battery electrolyte is poisono...

Page 98: ...nal battery side ways which could spill elec trolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the batter...

Page 99: ...ve a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteri...

Page 100: ...Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery...

Page 101: ...sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing stri...

Page 102: ...tandard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 mont...

Page 103: ...th a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds o...

Page 104: ...ntact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust...

Page 105: ...nt Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodi...

Page 106: ...lter Change the oil and filter See page 66 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter See page 81 Clean the air box Drain the sediment tube Fluid Levels Inspect the...

Page 107: ...and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 74 4 Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs 5 Tu...

Page 108: ...zed Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Stop the...

Page 109: ...5 cm Wheelbase 90 in 228 6 cm Cargo Box L x W x H 58 x 48 x 10 in 147 x 122 x 25 4 cm Ground Clearance 7 2 in 18 cm Min Turning Radius 180 in 457 2 cm Engine 4 valve 4 stroke twin cylinder with counte...

Page 110: ...tion Reverse 5 9 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 25 x 10 12 Tire Size Center Rear 25 x 11 12 Tire Pressure Front 8 12 psi 55 82 kPa Tire...

Page 111: ...4 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Pre...

Page 112: ...smission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from...

Page 113: ...uel Clogged fuel filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark...

Page 114: ...heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC...

Page 115: ...Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery volt...

Page 116: ...Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling...

Page 117: ...sts 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 deale...

Page 118: ...an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing...

Page 119: ...r replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHAL...

Page 120: ...117 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...118 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...119 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 123: ...Burning Belts 109 Button Mode 34 C Cap Fuel 33 Capacity Weight 53 Cargo 52 53 Cargo Box Dumping 54 Changing Coolant 75 Changing Gears 35 Changing Oil Front Gearcase 70 Middle Gearcase 71 Rear Gearcase...

Page 124: ...trol System 58 Exhaust System Warning 82 F Fan Cooling 76 Filling the Battery 97 Filter Care During Storage 103 Filter Cleaning Air 81 Filter Cleaning Fuel 81 Filter Systems 81 Filter Air 81 Filter Fu...

Page 125: ...arcase 71 Rear Gearcase 72 Transmission 69 O Oil Check Engine 65 Front Gearcase 70 Main Gearcase 68 Middle Gearcase 71 Rear Gearcase 72 Transmission 68 Oil Engine 64 67 Operation on Public Lands 58 Op...

Page 126: ...7 Storage Covers 104 Storage Fluid Levels 103 Storage Oil and Filter 103 Storage Removal 105 Switches 38 39 AWD Switch 39 Ignition 38 Light 39 T Tachometer 27 29 Throttle Freeplay Adjustment 84 Thrott...