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   Summary of Contents for Polaris Ranger 4x4 500 EFI

  • 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 contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 4

    • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

  • Page 5

    POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Specifications ......106 Polaris Products..... . . 108 Troubleshooting .

  • 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 keys.

  • Page 8: Safety

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

  • Page 9: Safety Decals And Locations

    SAFETY Safety Decals and Locations Discretionary Warning Age 16 Clutch Cover Warning 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 failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

  • Page 10: Discretionary Warning

    • With more than two passengers, or passengers under age five. • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt, the cab frame is not designed or intended to provide roll- over protection.

  • Page 11

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

  • Page 12

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 13

    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.

  • Page 14

    Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities.

  • Page 15

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

  • Page 16: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

  • Page 17

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

  • Page 18

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

  • 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 a RANGER requires your full attention.

  • Page 20

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice.

  • Page 21

    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition.

  • Page 22

    Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are...

  • Page 23

    SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury 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.

  • Page 24

    SAFETY Fuel Safety WARNING 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 or near the refueling area or where gasoline is stored.

  • Page 25: Features And Controls

    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 106. Cab Frame (if Equipped) Hip Bar...

  • Page 26: Component Locations

    FEATURES AND CONTROLS Component Locations Tailgate Tailgate Latch Release CV Boot/Rear Caliper Receiver Hitch Muffler (Spark Arrestor) 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 46-49.

  • Page 27

    FEATURES AND CONTROLS Console Fuel Gauge Park Brake Lever Indicator Gear Selector (Shifter) Lights Storage 12V Auxiliary Storage Compartment Holder Outlets Tray Auxiliary Outlets The 12-volt receptacles have 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.

  • Page 28: Indicator Lights

    FEATURES AND CONTROLS Indicator Lights The indicator light panel is located on the console. Low Gear Reverse (if equipped) Gear Brakes High High Neutral Temperature Gear Gear Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for the RANGER.

  • Page 29: Ignition Switch

    FEATURES AND CONTROLS Switches Light Switch AWD/Differential Switch Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.

  • Page 30: Light Switch

    FEATURES AND CONTROLS Switches Light Switch The ignition switch key must be in the ON/ RUN position to operate the headlights. Use the light switch to turn the headlights on or off. AWD/Differential Lock Switch The AWD/Differential Switch has three posi- tions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/ Turf Mode).

  • Page 31: Park Brake Lever

    FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, except neutral.

  • Page 32: Seat Belts

    FEATURES AND CONTROLS Seat Belts 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. Passengers under five years of age require special restraints, which are not available with this vehicle.

  • Page 33: Seat Removal

    FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehi- cle. 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.

  • Page 34: Brake Pedal

    FEATURES AND CONTROLS Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider pref- erence. Lift and hold the adjustment lever toward you while tilting the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

  • Page 35: Operation

    Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil...

  • Page 36

    OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 2. Check the oil level. See page 61. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

  • Page 37

    Ensure operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Brake light/tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced...

  • Page 38: Starting Engine

    OPERATION Starting 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.

  • Page 39: Stopping The Engine

    OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Apply the brakes. 4. Engage the park brake. WARNING A rolling vehicle can cause serious injury. Always engage the park brake after stopping the engine.

  • Page 40

    OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. 3. Practice starting and stopping (using the brakes) until you're famil- iar 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.

  • Page 41: Driving Procedure

    OPERATION Driving 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 ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 42: Driving On Slippery Surfaces

    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 con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2.

  • Page 43: Driving Uphill

    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. 15° maximum 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn.

  • Page 44: Driving Downhill

    OPERATION Driving on a Sidehill (Sidehilling) WARNING 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 operating on steep hills (15°...

  • Page 45: Driving Through Water

    The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum...

  • Page 46: Driving Over Obstacles

    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.

  • Page 47: Driving In Reverse

    OPERATION Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6.

  • Page 48: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in gear. 3. Engage the park brake. 4. Turn the engine off. 5. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury.

  • Page 49: Hauling Cargo

    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: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 50

    Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities Cargo Box (Level Ground) RANGER 4X4 500 EFI 1500 lbs. (681 kg) 1000 lbs. (454 kg) WARNING Driving with passengers in the...

  • Page 51: Dumping The Cargo Box

    OPERATION 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 creating hazardous driving conditions.

  • Page 52: Towing Loads

    OPERATION Towing Loads 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 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing.

  • Page 53: Parking The Vehicle

    OPERATION Parking the Vehicle WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake when stopping the engine. 1. Apply the brakes. Stop the vehicle on a level surface. 2. Turn the engine off. 3.

  • Page 54

    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 differen- tial. Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed.

  • Page 55: Disengaging Awd

    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.

  • Page 56: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on 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. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 57: Maintenance

    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 117.

  • Page 58: Periodic Maintenance Chart

    Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.

  • Page 59

    25 H Monthly Inspect level; change yearly (if equipped) Transmission oil 25 H Monthly Inspect level; change yearly Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services.

  • Page 60

    100 H Perform a break-in oil change at one month Oil filter change 100 H Replace with oil change Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services.

  • Page 61

    Auxiliary brake (if Inspect daily; adjust as equipped) needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services.

  • Page 62: Lubrication Recommendations

    Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil Polaris Premium 4 Synthetic See page 61. 0W40 Brake Fluid DOT 4 See page 84.

  • Page 63: Engine Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W- 40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient tem- perature operation.

  • Page 64

    Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil tank is located under the seat.

  • Page 65: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause 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 54. Always change the oil filter whenever changing oil.

  • Page 66

    MAINTENANCE Engine Oil Oil and Filter Change 10. Reattach the oil line. 11. Place shop towels beneath the oil filter. Using an oil fil- ter wrench, turn the filter counterclockwise to remove 12. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase.

  • Page 67

    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"...

  • Page 68: Gearcase Specification Chart

    Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris products. Oil Check The fill plug is located at the rear of the vehicle.

  • Page 69

    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.

  • Page 70

    Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

  • Page 71: Rear Gearcase

    Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris lubrication products. Oil Check Maintain the oil level even with the bottom thread of the fill plug hole.

  • Page 72

    MAINTENANCE Spark Plugs NOTICE 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 106. Spark Plug Gap/Torque Model Electrode Gap New Plug Used Plug Torque Torque RANGER 4X4 .036"...

  • Page 73: Spark Plug Condition

    MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

  • Page 74: Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 108 for the part numbers of Polaris prod- ucts. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

  • Page 75: Radiator And Cooling Fan

    Rein- stall the cap. NOTE: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer.

  • Page 76: Radiator Coolant Level

    MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 54. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.

  • Page 77

    • 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 it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 78: Pvt System

    MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys- tem. Use the following instructions to dry it out before operating. 1. Loosen the bottom screws that secure the clutch cover. Allow the water to drain.

  • Page 79: Vehicle Immersion

    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, fol- low the steps outlined below.

  • Page 80

    3. Check the belt webbing for wear, cuts or damage. If any irregulari- ties are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driving.

  • Page 81: Filter Systems

    Fuel Filter Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter.

  • Page 82

    MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line out the side of the air box and locate the filter. 3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clog-...

  • Page 83

    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 sufficiently before proceeding.

  • Page 84

    MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs located on the bottom of the muffler. 2. Shift the transmission to neutral. Apply the brakes. Start the engine.

  • Page 85: Throttle System

    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.

  • Page 86: Throttle Freeplay Adjustment

    MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster.

  • Page 87: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown.

  • Page 88: Brake Inspection

    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.

  • Page 89: Steering Wheel Inspection

    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 autho- rized Polaris dealer.

  • Page 90: Suspension Adjustments

    MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus- pension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting holes. 2. Reposition the shocks to the outside mounting holes. 3.

  • Page 91: Tire Tread Depth

    MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an 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 may adversely affect vehicle handling, which could result in vehicle damage or personal injury.

  • Page 92: Wheel Removal

    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. Apply the brakes. Engage the park brake.

  • Page 93: Wheel Installation

    MAINTENANCE Tires Wheel Installation 1. Place the transmission in gear. 2. Apply the brakes. Engage the park brake. 3. 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 rota- tion.

  • Page 94: Headlight Lamp Replacement

    MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 95: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 25 ft. (7.6 m) 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approxi- mately 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.

  • Page 96: Brake Lights

    MAINTENANCE Lights 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.

  • Page 97: Conventional Battery

    MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion.

  • Page 98: Battery Removal

    MAINTENANCE Battery 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. Battery Removal 1.

  • Page 99: Battery Installation

    MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 98 before installing the battery.

  • Page 100: Battery Storage

    See page 98. NOTE: Battery charge can be maintained by using a Polaris Battery 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 if the voltage drops below a pre-determined point.

  • Page 101

    MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 95. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

  • Page 102

    MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required...

  • Page 103

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

  • Page 104: Polishing The Vehicle

    • Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact 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 system.

  • Page 105

    MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 106: Storage Tips

    Make any necessary repairs and clean the vehicle as recommended. See page 100. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...

  • Page 107: Fluid Levels

    6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Storage Area/Covers Be sure the storage area is well ventilated.

  • Page 108: Removal From Storage

    4. Check all the points listed in the Daily Pre-Ride Inspection section on page 34. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.

  • Page 109: Specifications

    SPECIFICATIONS RANGER 4X4 500 EFI Maximum Weight Capacity 1500 lbs. (681 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1214 lbs. (551 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.25 qts.

  • Page 110

    Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Hand activated, mechanical Hood Headlights 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Indicator Light 1.0 W NOTE: See your Polaris dealer for clutching specifications.

  • Page 111: Polaris Products

    Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2870990 DOT 3 Brake Fluid 2872893 Engine Degreaser (12 oz.) 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger...

  • Page 112: Troubleshooting

    PVT system Clutch malfunction See your Polaris dealer. Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. See your dealer. Slippage from failure to...

  • Page 113

    Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...

  • Page 114

    TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...

  • Page 115

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range...

  • Page 116: Warranty

    ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial 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.

  • Page 117

    HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer.

  • Page 118

    If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.

  • Page 119

    Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 120: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 121

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 122

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 123: Index

    INDEX Accessory Outlets ....24 Capacity, Weight ....47 Adding Coolant ....71 Cargo .

  • Page 124

    INDEX Drivetrain Break-In....33 Fouled Plugs ....70 Driving Downhill ....41 Freeplay, Throttle .

  • Page 125: Oil Change

    Main Gearcase Oil Check ..65 Polaris Products ....108 Maintenance Log ... 117-119 Polishing the Vehicle.

  • Page 126

    INDEX Safety Decals ....5-7 Throttle Freeplay Adjustment..83 Safety Symbols ....9 Throttle Freeplay Inspection.

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