Polaris 500 Owner's Manual For Maintenance And Safety
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Polaris 500 Owner's Manual For Maintenance And Safety

Polaris offroad vehicle user manual
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  • Page 3 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. 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 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Specifications ......102 Polaris Products..... . . 106 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 Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
  • Page 10 The park/emergency brake lever will supply increased braking, but should be used as an emergency or parking brake only. READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.

  • Page 11: Operator Safety

    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 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, on your vehicle or in this manual, alerts you to the potential for injury.
  • Page 13 Operator Safety 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 Operator Safety 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. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power.
  • Page 18 Operator Safety 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 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 Operator Safety 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. 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 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 Operator Safety 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. 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

    Component Locations Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Cab Frame (if Equipped) Console Cargo Box Steering Wheel Storage Box (under driver’s seat)
  • Page 26 FEATURES AND CONTROLS Component Locations Headlights Radiator (if equipped) Hood Hold-Down Strap Front Bumper/Brush Guard...
  • Page 27 FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Taillights Tailgate Air Box CV Boot/Rear Caliper Receiver Hitch Muffler (Spark Arrestor)

  • Page 28: Indicator Lights

    FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console. See page 28. Low Gear Reverse (if equipped) Gear Brakes High High Neutral Temperature Gear Gear 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.

  • Page 29: Seat Removal

    FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

  • Page 30: Seat Belts

    Seat Belts 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. No person under the age of five may ride in the RANGER.
  • Page 31 FEATURES AND CONTROLS Console Indicator Lights Holder Storage Gear Selector (Shifter) Ignition Switch Storage Tray Choke Knob AWD/Differential Light Switch Switch Storage Accessory Compartment Outlet (with lid) Holder...

  • Page 32: Gear Selector

    Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for the RANGER. High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

  • Page 33: Brake Pedal

    FEATURES AND CONTROLS 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 Brake increase engine speed. Pedal Spring pressure returns the pedal to the rest position when released.

  • Page 34: Ignition Switch

    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 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 for your 4-cycle engine.

  • Page 36: Pre-Ride Inspection

    Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced OPERATION Page...

  • Page 37: Starting The Engine

    OPERATION Starting the Engine 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.

  • Page 38: Stopping The Engine

    Starting the Engine 8. After the engine starts, push the choke knob in half way. 9. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. 10. Push the choke knob in. Operating the vehicle immediately after starting could cause engine damage.

  • Page 39: Driving Safely

    OPERATION Driving Safely 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 40: Driving On Slippery Surfaces

    Driving Safely 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 41: Driving Uphill

    OPERATION Driving Safely 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. Proceed at a steady rate of speed and throttle opening. Climbing hills improperly can cause loss of control or vehicle overturn.

  • Page 42: Driving Downhill

    Driving Safely Driving on a Sidehill (Sidehilling) Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15°...

  • Page 43: 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 44: Driving Over Obstacles

    Driving Safely 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. Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle.

  • Page 45: Driving In Reverse

    Driving Safely 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 46: Parking On An Incline

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

  • Page 47: Hauling Cargo

    Driving Safely Hauling Cargo 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 48 Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model RANGER 4X4 RANGER 2X4 Driving with passengers in the cargo box can result in severe injury or...

  • Page 49: Dumping The Cargo Box

    OPERATION Driving Safely Dumping the Cargo Box 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 50: Towing Loads

    Driving Safely Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than the recommended vertical tongue weight on the towing bracket.

  • Page 51: Parking The Vehicle

    OPERATION Driving Safely Parking the Vehicle A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. Turn the engine off. 3. Engage the park brake. 4.
  • Page 52 Differential Operation Modes The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. On 4X4 models, engaging AWD locks the front differential and the rear differential. AWD (4X4) Press the top of the rocker switch to engage All Wheel Drive (AWD).

  • Page 53: Disengaging Awd

    OPERATION All Wheel Drive (AWD) (4X4 Models) The illuminated amber AWD switch indicates that the vehi- cle is in AWD. When the AWD switch is on, the front gearcase will auto- matically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

  • Page 54: 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 55: 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 121.

  • Page 56: Periodic Maintenance Chart

    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. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
  • Page 57 Oil (if equipped) Rear gearcase oil (if equipped) Transmission oil Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride...
  • Page 58 Oil filter change Oil tank vent hose Valve clearance Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 20 H...
  • Page 59 Toe adjustment Auxiliary brake (if equipped) Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M...

  • Page 60: Lubrication Recommendations

    Rear Gearcase Oil Prop Shaft U-joints Front Prop Shaft Yoke (4X4) Ball Joint Swing Arm Bushings Lube Polaris Premium 4 Synthetic 0W40 DOT 3 or DOT 4 Premium AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Premium ATV Angle Drive...

  • Page 61: 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 62: Oil Check

    Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil tank is located under the seat.

  • Page 63: Oil And Filter Change

    Engine Oil Oil and Filter Change Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil.
  • Page 64 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 65 Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.
  • Page 66 Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 106 for the part numbers of Polaris products. Oil Check The fill plug is located at the rear of the vehicle.
  • Page 67 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 68 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 106 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 69: Rear Gearcase

    Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 106 for the part numbers of Polaris lubrication products. Oil Check The rear gearcase fill plug is on the driver's side of the rear gearcase.

  • Page 70: Spark Plugs

    Spark Plugs Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model Electrode Gap RANGER 4X4 .036" (.9 mm) RANGER 2X4 Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 71: 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 72: 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 106 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 73: Coolant Level

    Reinstall 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. CAUTION Overflow Bottle...

  • Page 74: Radiator Coolant Level

    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 52. 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 75 • 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 76: Pvt System

    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 77: Vehicle Immersion

    Vehicle Immersion 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 78: 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 79 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...
  • Page 80 Carburetor The idle speed adjustment should be performed as outlined in the Peri- odic Maintenance Chart, or whenever the idle speed is changed. Recom- mended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure.

  • Page 81: Spark Arrestor

    MAINTENANCE Spark Arrestor 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 82: Throttle System

    Throttle System 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 83: Throttle Freeplay Adjustment

    Throttle System Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster. 3. Squeeze 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.

  • Page 84: Brake Fluid

    Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30. Brake Fluid Inspect the brake system rou- tinely. Inspect the level of the brake fluid before each opera- tion.

  • Page 85: Brake Inspection

    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 86: Steering Wheel Inspection

    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. Suspension Adjustment The rear suspension may be adjusted to provide a stiffer suspension if necessary.
  • Page 87 If any irregularities 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 driv- ing.

  • Page 88: Tire Tread Depth

    Tires 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 89: 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. Stop the engine. Place the transmission in gear. Engage the park brake.

  • Page 90: Headlight Lamp Replacement

    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. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 91: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 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. 3.

  • Page 92: Indicator Lamp Replacement

    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 93: 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. Conventional Battery Always keep battery terminals and connections free of corrosion.

  • Page 94: Battery Removal

    Battery 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 95: 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 94 before installing the battery.

  • Page 96: Battery Storage

    See page 94. 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 97 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 91. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 98 Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less MAINTENANCE Action charger @ standard amps...

  • Page 99: Cleaning And Storage

    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 100: Washing 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 101 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 102: Fluid Levels

    Make any necessary repairs and clean the vehicle as recommended. See page 96. Stabilize the Fuel 1. Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.

  • Page 103: Battery Maintenance

    5. Treat the fuel system with Polaris Carbon Clean. See page 99. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

  • Page 104: Removal From Storage

    33. 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 52. Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.

  • Page 105: Specifications

    Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Engine Displacement Bore x Stroke...
  • Page 106 Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for jetting and clutching specifications. SPECIFICATIONS RANGER 2X4 Dry Sump 0W/40 Single Lever (console) 8.71:1 5.9:1 3.83:1 3.70:1...
  • Page 107 Gross Vehicle Weight Dry Weight Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Engine Displacement Bore x Stroke...
  • Page 108 Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light NOTE: See your Polaris dealer for jetting and clutching specifications. SPECIFICATIONS RANGER 4X4 Dry Sump 0W/40 Single Lever (console) 8.71:1 5.9:1 3.83:1 3.83:1...

  • Page 109: Polaris Products

    2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2870990 DOT 3 Brake Fluid 2872893 Engine Degreaser (12 oz.) 2871956 Loctite 2871076 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 110: Troubleshooting

    Dry out the PVT. See page 73. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
  • Page 111 Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs and replace if necessary Immediately see your Polaris dealer Inspect, clean and/or replace spark plug Recharge the battery to 12.8 VDC See your dealer...
  • Page 112 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range 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...
  • Page 113 Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Overuse of choke Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...

  • Page 114: 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 115 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 116 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 117 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 118 Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner's Warranty Responsibilities: • As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's...
  • Page 119 California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with...
  • Page 120 (iii) Filter lock assy (gaseous fuel, if applicable) If an authorized dealer determines that other LSI engine components have been dam- aged due to the failure of a warranted emission-related part during the warranty period, POLARIS will repair and/or replace the necessary components.

  • Page 121: Maintenance Schedule

    When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
  • Page 122 More often under severe use, such as dirty or wet conditions. Due to the nature of these adjustments, it is recommended that an authorized Polaris dealer perform service. Do not attempt to perform this work unless you are familiar with mechanical repair.
  • Page 123 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emis- sion-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appro- priate dealer where the warranty repair is to be performed.

  • Page 124: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 125 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 126: Index

    Adding Coolant....69 Adjustment Headlight Beam ... . 88 Park Brake....82 Rear Spring .

  • Page 127: Front Gearcase

    Electromagnetic Interference..51 Emission Control, Crankcase..51 Emission Control, Exhaust ..51 Emission Control, Noise ..51 Emissions Limited Warranty .

  • Page 128: Oil Change

    Spark Plug....67 Polaris Products ....106 Polishing the Vehicle ... . 97 Premium 4 Synthetic Oil .
  • Page 129 INDEX Storage ....96-100 Storage and Inspection... 99 Storage and Lubrication..99 Storage Area .

This manual is also suitable for:

2007 ranger 500 2x4Ranger 4x4 500 efi 2007

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