Polaris RANGER 500 2022 Owner's Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. RANGER 500 2022
  6. Owner's manual

Polaris RANGER 500 2022 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

2022
For Maintenance and Safety
OWNER'S
MANUAL
RANGER 500

Advertisement

Table of Contents
loading

Related Manuals for Polaris RANGER 500 2022

Summary of Contents for Polaris RANGER 500 2022

  • Page 1 2022 For Maintenance and Safety OWNER’S MANUAL RANGER 500...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR Code® with your smartphone.
  • Page 3 2022 Owner’s Manual RANGER 500...
  • Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Recreational Off-Highway Vehicle Association® and ROHVA® are registered trademarks Recreational Off-Highway Vehicle Association. BatteryMINDer® is a registered trademark of VDC Electronics Inc. Loctite® is a registered trademark of Henkel Corporation. NYOGEL® is a registered trademark of Nye Lubricants, Inc.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 SAFETY SYMBOLS AND SIGNAL WORDS 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 7: Table Of Contents

    Specifications ....129 POLARIS Products ....131 Troubleshooting ....133 Warranty .

  • Page 9: Introduction

    Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 10 (IF EQUIPPED) Some Polaris vehicles come equipped with a near-field communication (NFC) chip. The NFC chip is embedded in the Polaris emblem located at the front of the vehicle and seamlessly connects you to a digital platform of vehicle information and tools. See your dealer for more information.
  • Page 11 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.

  • Page 13: Safety

    SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA® (Recreational Off-Highway Vehicle Association®) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751.
  • Page 14 SAFETY RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area. The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow.
  • Page 15 HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 16 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to obtain a replacement. Replacement safety labels are provided by POLARIS at no charge. Seat Belt / Driver Warning...
  • Page 17 SAFETY SHIFT CAUTION CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position. Part Number: 7181060. SEAT BELT / DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared...
  • Page 18 SAFETY PROPER USE WARNING WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. • Do not let people drive or ride after using alcohol or drugs. •...
  • Page 19 SAFETY PASSENGER/TIRE PRESSURE WARNING The Passenger/Tire Pressure Warning is located in the cargo box. WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 20 SAFETY SAFETY LABELS (ISRAEL VEHICLES ONLY) GENERAL ALERT (7184006) • Read the owner’s manual. • Never allow anyone under 16 years of age to operate this vehicle. • Never use alcohol or drugs before or while driving or riding. • This vehicle may be used on public roads.
  • Page 21 SAFETY PASSENGER / TIRE PRESSURE WARNING WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. • Read the Owner’s Manual. • Never carry fuel on this vehicle. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 22 SAFETY CLUTCH COVER ALERT (7181427) Keep body parts away from belt. Label Location: on the clutch cover. HITCH CAPACITY ALERT (7183975) Read the owner’s manual. MAXIMUM DRAWBAR PULL: 1700 N ON LEVEL GROUND MAXIMUM VERTICAL LOAD: 1100 N...
  • Page 23 SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.
  • Page 24 • Always follow proper procedures for turning. 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.
  • Page 25 SAFETY • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. •...
  • Page 26 SAFETY USING ALCOHOL OR DRUGS WARNING Never consume alcohol or drugs before or while operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
  • Page 27 SAFETY OPERATING WITH A LOAD ON THE VEHICLE The weight of the cargo, operator, and passengers impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.
  • Page 28 SAFETY CAB DOORS (IF EQUIPPED) Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests.
  • Page 29 SAFETY JUMPS AND STUNTS CAUTION Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. TURNING IMPROPERLY CAUTION Turning improperly could cause loss of traction, loss of control, accident or rollover.
  • Page 30 SAFETY STALLING WHILE CLIMBING A HILL CAUTION Stalling or rolling backwards while climbing a hill could cause a rollover. 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 31 SAFETY SKIDDING OR SLIDING CAUTION Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 32 SAFETY OPERATING ON FROZEN BODIES OF WATER WARNING Serious injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.
  • Page 33 SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
  • Page 34 EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 35: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS ROPS Frame Cargo Box Hip Bars Fuel Cap Front Bumper/Brush Guard Headlights Radiator Tailgate...
  • Page 36 FEATURES AND CONTROLS CONSOLE Cup Holder 12V Auxiliary Outlet Instrument Cluster Steering Wheel Adjustment Lever MODE Button Ignition/Light Switch Gear Selector Storage Tray AWD Switch Storage Compartment AUXILIARY OUTLET The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights.
  • Page 37 FEATURES AND CONTROLS SWITCHES 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. The engine is off. Electrical circuits are off, except Acc, 12V. Lights On Lights are on.
  • Page 38 FEATURES AND CONTROLS AWD/ADC DRIVE MODE SWITCH The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge. Drive mode options include: • All Wheel Drive (AWD/4X4) • ADC All Wheel Drive (ADC 4X4) •...
  • Page 39 R: Reverse P: Park Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.
  • Page 40 FEATURES AND CONTROLS USING LOW GEAR Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK. Always shift into low gear for any of the following conditions.
  • Page 41 EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 42 FEATURES AND CONTROLS THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. This vehicle is equipped with an automatic throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle.
  • Page 43 FEATURES AND CONTROLS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 44 Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Your POLARIS dealer or qualified technician can assist. SECURING THE NET 1.
  • Page 45 If your factory-installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, you may need to purchase a 30 AH battery and a battery strap bracket. Your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 46 FEATURES AND CONTROLS INSTRUMENT CLUSTER Speedometer Indicator Lamps Mode Button Rider Information Center...
  • Page 47 Power Steering turned to the ON position. If light remains on, the EPS (EPS) Warning system is inoperative. See your POLARIS dealer, or (if equipped) other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 48 FEATURES AND CONTROLS RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. 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.
  • Page 49 FEATURES AND CONTROLS Lo [VOLTAGE] – Battery voltage is too low (below 11V). Drive at a higher RPM or recharge the battery to clear the warning. Ov [VOLTAGE] – High electrical load has been applied to the battery (above 15V) or there is a possible issue with another vehicle component.
  • Page 50 FEATURES AND CONTROLS MODE BUTTON The button located on the face of the instrument cluster is used to toggle through available mode options in the following order: • Odometer • Trip Meter • Tachometer • Hour Meter • Service Interval •...
  • Page 51 FEATURES AND CONTROLS CLOCK MODE The clock must be reset any time the battery has been disconnected or discharged. To set the clock time, do the following: 1. Turn key to the ON position. Use the Mode Button to toggle to the odometer display.
  • Page 52 DIAGNOSTIC DISPLAY MODE The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer or other qualified technician can provide all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is activated after the key is turned on. Leave key ON to view the active code (failure code).
  • Page 53 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the Mode Button to advance to the next error code. 5. PRESS and HOLD the Mode Button to exit the diagnostics menu. Your authorized POLARIS dealer can provide code details and diagnosis.

  • Page 55: Operation

    OPERATION OPERATION IMPORTANT INFORMATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
  • Page 56 OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. PVT BREAK-IN (CLUTCHES/BELT) Always break in the clutches and drive belt of new vehicles, as well as after a belt replacement.
  • Page 57 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for on-road use).
  • Page 58 Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 59 OPERATION 5. 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. 6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds.
  • Page 60 OPERATION PARKING THE VEHICLE 1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
  • Page 61 OPERATION 14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed. WARNING Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death.
  • Page 62 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (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.
  • Page 63 OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: • Avoid excessively steep hills. • ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. • Always travel straight uphill. • Keep both feet on the floor. •...
  • Page 64 OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can provide this service.
  • Page 65 OPERATION PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
  • Page 66 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 67 OPERATION Loads should be centered on the vehicle and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual.
  • Page 68 OPERATION TOWING LOADS WARNING 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.
  • Page 69 OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3.
  • Page 70 OPERATION ALL WHEEL DRIVE (AWD) SYSTEM The standard All Wheel Drive system is All-Wheel Drive (AWD) controlled by the AWD switch. When the switch is in the 2X4 position , the Two-Wheel Drive (2WD) vehicle is in two-wheel drive at all times. When the switch is in the AWD position , the vehicle is in all wheel drive and the 4X4 indicator in the instrument...
  • Page 71 OPERATION ENGAGING AWD Press the top of the switch to engage All All-Wheel Drive (AWD) Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information Differential Lock center to indicate that the vehicle is in Differential Unlock AWD.When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction.
  • Page 72 OPERATION 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer or other qualified service person for service. LOCKING THE DIFFERENTIAL Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD).
  • Page 73 OPERATION ALL WHEEL DRIVE/ACTIVE DESCENT CONTROL SYSTEM ADC models are equipped with a drive mode switch that controls the AWD system. The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge. DRIVE MODE OPERATION Use the drive mode switch to engage AWD (4X4), ADC 4X4, TURF mode or 2X4.
  • Page 74 OPERATION DRIVE MODE INDICATOR The Drive Mode Indicator displays the active drive mode. The Drive Mode Indicator will match the information displayed in the Rider Information Center. An amber light flashes when drive mode selection is pending. Once in the selected drive mode, a solid amber light will show next to the active drive mode.

  • Page 75: Winch Guide

    WINCH GUIDE WINCH GUIDE WINCH SAFETY These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 76 WINCH GUIDE 12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
  • Page 77 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 78 Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer.
  • Page 79 WINCH GUIDE • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead. • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation.
  • Page 80 WINCH GUIDE c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d.
  • Page 81 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 82 Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
  • Page 83 WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 84 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 85: Emission Control Systems

    EMISSION CONTROL SYSTEMS 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 vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1a.

  • Page 87: Maintenance

    Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 88 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized dealer or other qualified person perform these services. Emission Control System Service (California) WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
  • Page 89 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES CLNDR (KM) Brake pad wear Monthly Inspect periodically 10 H Battery Monthly Check terminals; clean; test 20 H Inspect; Cycle the Key to pressurize the fuel pump; Fuel System Monthly 25 H check lines and fittings for leaks and abrasion.
  • Page 90 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES CLNDR (KM) Cycle the key to prime and pressurize the fuel system. 1000 Fuel System Check for leaks at fuel cap, 100 H 12 M (1600) fuel line / rail, and fuel pump; Replace lines every 2 years Inspect;...
  • Page 91 MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
  • Page 92 POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 93 MAINTENANCE OIL CHECK WARNING Continuous contact with used motor oil has caused skin cancer in laboratory animal tests. Avoid prolonged contact. Wash skin with soap and water. Launder or discard soiled clothing. The oil dipstick and fill tube is located on the engine. Access the dipstick through the right rear wheel well.
  • Page 94 MAINTENANCE OIL AND FILTER CHANGE Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. The engine drain plug is located on the bottom of the crankcase. To change the oil and filter , do the following: 1.
  • Page 95 MAINTENANCE 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter O-ring is completely removed. 10. Lubricate the O-ring on the new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.
  • Page 96 MAINTENANCE GEARCASES TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. TORQUE Transmission Drain / Fill Plug: 14 ft-lbs (19 Nm) OIL CHECK The fill plug is located on the rear of the gearcase.
  • Page 97 MAINTENANCE FLUID CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate. 1. Insure the engine is off and remove the fill plug 2. Place a drain pan under the drain plug 3.
  • Page 98 MAINTENANCE FRONT GEARCASE (DEMAND DRIVE) Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications.
  • Page 99 MAINTENANCE 9. Check for leaks. 10. Discard used oil properly. GEARCASE SPECIFICATION CHART DRAIN PLUG/ FILL PLUG LEVEL GEARCASE LUBRICANT CAPACITY TORQUE CHECK PLUG TORQUE AGL Gearcase Transmission 41 fl oz 10–14 ft-lbs 10–14 ft-lbs Lubricant & (Main (1200 mL) (14–19 N·m) (14–19 N·m) Transmission...
  • Page 100 Refer to the Specifications section 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 or their equivalent. SPARK PLUG GAP/TORQUE MODEL ELECTRODE GAP...
  • Page 101 MAINTENANCE 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 indicates the proper type and heat range for the engine and the service. The tip should not be white.
  • Page 102 ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 103 MAINTENANCE RADIATOR COOLANT LEVEL Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan.
  • Page 104 4. Use a funnel and slowly add coolant as needed. 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part. OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart.
  • Page 105 • See your dealer or other qualified service person 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 106 MAINTENANCE BELT REPLACEMENT / DEBRIS REMOVAL If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt. WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
  • Page 107 12. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist. Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.
  • Page 108 6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.
  • Page 109 6. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 7. If water has been ingested into the PVT follow the procedure for drying.
  • Page 110 MAINTENANCE FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart. 1. Lift the cargo box. 2. Clean all dirt and debris from the air box area. 3. Unlatch the two (2) cover clips and carefully remove the air box cover. Inspect the seal between the cover and air box to ensure the seal is not torn and has been maintaining a proper seal.
  • Page 111 NOTICE Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. See page 92 for the part numbers of POLARIS products. 7. Make sure the filter is fully seated on the intake boot and that there is no gap between the filter and boot after installation.
  • Page 112 MAINTENANCE SPARK ARRESTOR WARNING • Never operate the vehicle without the spark arrestor. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 113 MAINTENANCE 7. Repeat steps 4 and 5 until no more particles are expelled when the engine is revved. 8. Stop the engine. Allow the arrestor to cool. 9. Reinstall the arrestor plug and remove the outlet cover or plug. BRAKES The front and rear brakes are hydraulic disc type brakes.
  • Page 114 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40® or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.
  • Page 115 MAINTENANCE SUSPENSION ADJUSTMENT Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension. Always heed the following rules if you make adjustments to this suspension. • Always return the suspension to the lowest (softest ) setting after the load is removed from the vehicle.
  • Page 116 MAINTENANCE STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart section. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3.
  • Page 117 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. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
  • Page 118 MAINTENANCE TIRE TREAD DEPTH Always replace tires when tread depth is worn to 3 mm (1/8”) or less. WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4.
  • Page 119 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. The fuse box is located in the electrical compartment under the left rearmost seat.
  • Page 120 MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
  • Page 121 MAINTENANCE HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 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.
  • Page 122 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. Your vehicle has a low-maintenance battery.
  • Page 123 If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.
  • Page 124 MAINTENANCE STATE OF VOLTAGE (DC) ACTION CHARGE TIME* CHARGE 100% 12.8-13.0 volts None, check None required monthly 75%-100% 12.6-12.8 volts May need slight 3-6 hours charge, if no charge given, check in 2 weeks 50%-75% 12.3-12.6 volts Needs charge 5-11 hours 25%-50% 12.0-12.3 volts Needs charge...
  • Page 125 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 126 Replacement safety labels are provided by POLARIS at no charge. POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 127 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 128 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.
  • Page 129 MAINTENANCE 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection. Tightness of the bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart. TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle.

  • Page 131: Specifications

    SPECIFICATIONS SPECIFICATIONS RANGER 500 Maximum Weight Capacity (includes 1000 lbs. (454 kg) weight of operator, passenger, cargo, accessories) Dry Weight 1080 lbs. (490 kg) Test GVW - Rollover Protection System 2255 lbs. (1023 kg) per OSHA® 29 CFR (ROPS) 1928.53 Fuel Capacity 8.8 gal.
  • Page 132 SPECIFICATIONS Ignition Timing ECU Controlled Spark Plug Autolite® 5924 / 0.030” - 0.037” (0.85 +/- 0.08 mm) Lubrication System Wet Sump Cooling Liquid Front Suspension MACPHERSON® Strut w/9 in. (22.7 cm) of travel Rear Suspension Dual A-arm, Anti-Sway Bar w/10 in. (25.4 cm) of travel Throttle Body Size 40 mm...

  • Page 133: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 12 fl oz (355 mL) 2870791 aerosol Fogging Oil 1 qt (0.95 L) 2871517 1 qt (0.95 L) 2876244 2 qt (1.90 L) PS-4 2877490 1 gal (3.8 L) 2876245 1 qt (0.95 L)
  • Page 134 POLARIS PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 2.5 gal (9.5 L) 2872280 DOT 4 Brake Fluid — 2872189 Loctite® 565 Thread — 2871956 Sealant POLARIS Battery — 2859044 Tender Charger...

  • Page 135: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground speed – 3–7 mph (4.8–11.3 Drive at a higher speed or use low range more frequently.
  • Page 136 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel...
  • Page 137 TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug...
  • Page 138 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre-filter Inspect and clean (with soapy water) or replace Other mechanical failure Your authorized dealer can assist Overheated engine...

  • Page 139: Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 140 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 141 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 142 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 143 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 144 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.
  • Page 145 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...
  • Page 146 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
  • Page 147 As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

  • Page 149: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 151 Clothing........13 Clutch Cover Alert ..... 20 Active Descent Control ....72 Cold Weather Operation....56 Adding or Changing Coolant ..100 Component Locations....33 Age Restrictions ......23 Cooling System....... 100 Air Filter......... 108 Crankcase Emission Control Air Filter / Air Box..... 125 System ........
  • Page 152 Improper Tire Maintenance ..26 Indicator Lamps ......45 Failure to Inspect Before Inspect and Lubricate ....125 Operating ....... 24 Instrument Cluster ..... 44 Fan, Cooling......100 Fluid Levels......125 Fluid Part Numbers ....131 Fog the Engine ....... 126 Front Gearcase (Demand Drive) ...
  • Page 153 Warning ......... 17 Periodic Maintenance Chart ..85 Shift Alert (7183987) ....18 Plugs, Spark......98 Shock Loading the Winch .... 81 Polaris Products ...... 131 Signal Words ......4 POLARIS Variable Spark Arrestor ......110 Transmission (PVT) System Spark Plug Gap/Torque....98 Spark Plug Inspection....
  • Page 154 Tire Tread Depth ......116 Tires ........115 Towing Loads ......66 Trail Etiquette ......56 Trailer Hitch Bracket....43 Transmission ......94 Transporting the Vehicle.... 127 Turning Improperly..... 27 Unauthorized Use of the Vehicle ... 32 Vehicle Identification Numbers ..9 Vehicle Immersion ....
  • Page 156 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Part No. 9940320 Rev 02 Medina, MN 55340 Printed in USA...

Table of Contents