RANGER® 500 Midsize RANGER CREW® 500 Owner's Manual for Maintenance and Safety
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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: If you are under age 16 and without a valid driver’s license. At speeds too fast for your skills or the conditions. After or while using Alcohol or Drugs. On hills steeper than 15 degrees 15 . On public roads. A collision can occur with another vehicle.
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® • Low Emission Vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS, RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc. Copyright 2012 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 discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Maintenance . . . . . . . . . . . .
INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.
INTRODUCTION 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.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
SAFETY Safety Labels and Locations Discretionary Warning (500 Midsize) WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On hills steeper than 15 degrees 15°. • On public roads, a collision can occur with a another vehicle. • With more than one passenger, or a passenger under age twelve or who cannot comfortably reach the floor and hand holds.
SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning (500 Midsize) WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. X Maximum Box Load 500 lbs. (227 kg) IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT TIRE - INFLATE TO 10 psi (68.9 kPa) REAR TIRE - INFLATE TO 12 psi (82.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothing for comfort and to reduce the chance of injury. Long Sleeves Helmet Long Wearing a helmet can prevent a severe Pants head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Gloves Approved helmets in the USA and Canada bear a U.S. Department of TransporOver-the-Ankle Boots tation (DOT) label.
SAFETY Operator 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 under age 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY Operator Safety • 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.
SAFETY Operator Safety Equipment Modifications 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 vehicle create a substantial safety hazard and increase the risk of bodily injury.
SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license.
SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
SAFETY Operator Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident.
SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 35. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Apply the brakes.
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets. Not all models come with all features. Refer to the specifications section beginning on page 74.
FEATURES AND CONTROLS Console Auxiliary Outlet The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood. Mode Button Instrument Cluster Storage Compartment Mode Button The yellow button located near the instrument cluster is used to toggle through mode options available. See pages 26-28.
FEATURES AND CONTROLS Switches Ignition Switch Light Switch AWD/Differential Switch Ignition Switch/Light Switch The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF The engine is off. Electrical circuits are off, except Acc, 12V. LIGHTS ON Lights are on. Electrical circuits are on. Electrical equipment can be used. LIGHTS OFF Lights are off. Electrical circuits are on. Electrical equipment can be used.
FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch 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 38-39. Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed.
FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats. Always make sure the seat belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER. To wear the seat belt properly, follow this procedure: 1.
FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover. WARNING! Vehicle rollover could cause severe injury or death.
FEATURES AND CONTROLS Instrument Cluster The instrument cluster measures distance traveled by the vehicle, as well as time, hours of operation and engine RPM. Speedometer Speedometer Needle Tip: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 18. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button until the total changes to 0.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Blink Code Descriptions Blink Code -21 45 46 22 22 23 42 42 51 51 51 52 52 52 53 53 53 54 54 54 55 55 55 56 56 56 57 57 57 58 58 58 41 41 61 Failure Description No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground Engine Temp Senso
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. 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 break-in period.
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 20 60 Brake fluid Ensure proper level 60 Park gear Ensure vehicle does not roll when in PARK. Ensure PARK light illuminates.
OPERATION Starting Engine 1. 2. 3. 4. Always start the engine outdoors or in a well-ventilated area. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. Apply the brakes. Place the transmission in PARK. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts. 5.
OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Sit in the driver's seat and fasten the seat belt. 3. Start the engine and allow it to warm up. 4. Always use the cab nets while riding in this vehicle. 5. Apply the service brakes and shift the transmission into gear. 6. Check your surroundings and determine your path of travel. 7.
OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slip15° maximum pery or loose surfaces. 6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 7. Never go over the crest of a hill at high speed.
OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 56, and take the vehicle to your dealer at the first opportunity.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2.
OPERATION Hauling Cargo WARNING Hauling cargo 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 hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 38. Towing a trailer increases braking distance. 3. Do not tow more than the recommended weight for the vehicle.
OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed. See page 41 for AWD operating instructions.
OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 85.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering Front suspension Rear suspension Tires Pre-Ride Brake fluid level Make adjustments as need ed. See Pre-Ride Checklist on page 31.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine oil change 100 H 6M - Perform a break-in oil change at one month Oil filter change 100 H 6M - Replace with oil change Front Gearcase oil (if equipped) 100 H 6M - Inspect level; change yearly Middle Gearcase oil (if equipped) 100 H 6M - Inspect level; change yearly Rear gearcase oil (if equipped) 100 H 6M - Inspect level; change yearly Tr
MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 4. Clean the area around the drain plug. Drain Plug 5. Place a drain pan beneath oil tank. CAUTION! Hot oil can cause burns to skin.
MAINTENANCE Engine Oil Oil and Filter Change 11. Reattach the oil line. 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 14. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Make sure the gasket from the old filter is not still on the engine. 15.
MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug(s) Torque Drain Plug Torque Main Gearcase (Transmission) Premium AGL Synthetic Gearcase Lube 34 oz. (1000 ml) 12 ft. lbs. (16.3 Nm) 12 ft. lbs. (16.3 Nm) Front Gearcase Demand Drive Plus Fluid 9.3 oz. (275 ml) 8-10 ft. lbs. (11-13.6 Nm 11 ft. lbs.
MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 76 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase. 1.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 74 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark Plug Gap/Torque Model Electrode Gap 500 Midsize .036" (.9 mm) CREW 500 .036" (.9 mm) New Plug Torque 9-11 ft. lbs. (12-15 Nm) 9-11 ft. lbs.
MAINTENANCE Cooling System 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 (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface. 2. Lift the hood. View the coolant level in the overflow bottle. 3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid.
MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug. 3. Place the transmission in PARK. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land or at the very least, to water below the footrests. 2. Dry any water present in the air box. Filter replacement is required if water is present. 3.
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. 1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the Air Filter gasket. It should adhere tightly to the cover and seal all the way around.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. • Remove any combustible materials from the area. • Wear eye protection and gloves. • Do not stand behind or in front of the vehicle while purging.
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasionally during 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.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 20. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 6. Apply the brakes. Place the transmission in PARK. Stop the engine. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.
MAINTENANCE Lights Headlight Beam Adjustment X X 8" (20 cm) 25 ft. (7.6 m) 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. Apply the brakes. Start the engine. Turn on the headlights. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall.
MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
MAINTENANCE Battery Battery Removal WARNING 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 last. 1. Remove the front seat. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last. 4.
MAINTENANCE Battery Battery Installation Using a new battery that 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 69 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the fully charged battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 67. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 68. Make sure the positive terminal is toward the driver’s side of the vehicle.
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. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 43. Battery Maintenance See pages 68-69 for storage and charging procedures. Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 43.
MAINTENANCE Removal from Storage 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 with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 31. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5.
SPECIFICATIONS RANGER 500 Midsize Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. Turning Radius Towing Capacity Hitch Tongue Capacity Max.
SPECIFICATIONS Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlights Taillights Brake Light Indicator Light RANGER 500 Midsize RANGER CREW 500 PVT Single Lever (console) 7.70:1 7.00:1 4.12:1 3.818:1 25 x 8 - 12 25 x 11 - 12 10 psi (68.9 kPa) 12 psi (82.
POLARIS PRODUCTS Part Number Description 2870791 Fogging Oil (12 oz./355 ml Aerosol) Engine Lubricant 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) 2878068 AGL PLUS Transmission Fluid (qt./.95 l) Gearcase / Transmission Lubricants 2878069 AGL PLUS Transmission Fluid (gal./3.8 l) 2877922 Demand Drive Plus Fluid (qt./.95 l) 2877923 Demand Drive Plus Fluid (gal./3.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer 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 Slow/easy clutch engagement Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slip
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE 86 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments Shock Spring . . . . . . . . . . . . . . . . . . . . 61 Throttle Freeplay . . . . . . . . . . . . . . . . . 59 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive Switch . . . . . . . . . . . . . . . . . . . . Auxiliary Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . AWD Diagnostics . . . . . . . . . . .
INDEX F Fastener Torque, Cylinder Head/Base. . . . . . . . . Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Change Engine Oil . . . . . . . . . . . . . . . . . . . 47-48 Front Gearcase . . . . . . . . . . . . . . . . . . 50 Main Gearcase . . . . . . . . . . . . . . . . . . 49 Transmission . . . . . . . . . . . . . . . . . . . .
INDEX P S Parking on an Incline . . . . . . . . . . . . . . . . . . . . . . 37 Parking the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 37 Periodic Maintenance Chart . . . . . . . . . . . . . . 43-45 Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Plug, Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . .
