Polaris RANGER 500 EFI 4X4 2011 Owner's Manual
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Polaris RANGER 500 EFI 4X4 2011 Owner's Manual

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PMS 419
RANGER
500 EFI 4X4
500 EFI CREW
Owner's Manual
for Maintenance and Safety

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Table of Contents

Troubleshooting

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Summary of Contents for Polaris RANGER 500 EFI 4X4 2011

  • Page 1 PMS 419 RANGER 500 EFI 4X4 500 EFI CREW Owner's Manual for Maintenance and Safety...
  • Page 2 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 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 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. Vehicle rollover could cause severe injury or death.
  • Page 5 • Victory Motorcycles ® • Low Emission Vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever pro-...
  • Page 6 POLARIS, THE WAY OUT, RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc. Copyright 2010 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 7: Table Of Contents

    Specifications......104 POLARIS Products ......106 Troubleshooting .
  • Page 8 INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used.
  • Page 9 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. A...

  • Page 10: 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 11: Safety

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are pro- vided by POLARIS at no charge. The part number is printed on the label. Passenger/Tire Pressure Warning (4X4) WARNING •...
  • Page 12 SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning (Crew) WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING Maximum Box Load 500 lbs. (227 kg) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

  • Page 13: Safety

    SAFETY Safety Labels and Locations Discretionary Warning Shift Caution Age 16 Warning Clutch Cover Warning Clutch Cover Warning WARNING • 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 14 • 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. Vehicle rollover could cause severe injury or death.
  • Page 15 • 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. Vehicle rollover could cause severe injury or death.

  • Page 16: Operator Safety

    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 17 Never turn at exces- sive 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 18 Gasoline is extremely flammable. See page 17 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 19: Equipment Modifications

    SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a POLARIS RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these pur- poses.

  • Page 20: Age Restrictions

    SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

  • Page 21: Handling Gasoline

    SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times.

  • Page 22: Operating On Pavement

    SAFETY Operator Safety Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn.

  • Page 23: Improper Hill Climbing

    SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 46. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill.

  • Page 24: Features And Controls

    FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. The vehicle illustrated below is shown without cab nets only to allow com- ponent identification.

  • Page 25: Trailer Hitch Bracket

    FEATURES AND CONTROLS Component Locations Tailgate Latch Releases Tailgate Muffler (Spark Arrestor) Receiver Hitch CV Boot/Rear Caliper 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 52-55.
  • Page 26 FEATURES AND CONTROLS Console Storage Mode Instrument Compartment Button Cluster Storage Gear Selector Cup Holder 12V Auxiliary Tray (Shifter) Outlet Auxiliary Outlet The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood.

  • Page 27: Mode Button

    FEATURES AND CONTROLS Console Mode Button The yellow button located near the instrument cluster is used to toggle through mode options available. See pages 33-36. Gear Selector Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER.
  • Page 28 FEATURES AND CONTROLS Switches AWD/Differential Ignition Switch Light Switch Switch Ignition Switch/Light Switch The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V.

  • Page 29: Brake Pedal

    FEATURES AND CONTROLS Switches AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode). Press the top of the rocker switch to engage All Wheel Drive (AWD). See page 57 for AWD operating instructions. Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD).
  • Page 30 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats.The center seat is equipped with a lap-style seat belt. Always Latch Plate make sure the seat belts are secured for all riders before operating.

  • Page 31: Seat Belt Inspection

    If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.
  • Page 32 Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, avail- able from your authorized Polaris dealer. Securing a Net 1. After entering the vehicle, insert the lower net rod into the net mount on the floor.

  • 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: Storage Compartments

    The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your autho- rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover.

  • Page 35: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster The instrument cluster measures distance traveled by the vehicle, as well as time, hours of operation and engine RPM. Speedometer Speedometer Needle Rider Information Center Tip: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists.

  • Page 36: Rider Information Center

    Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the elec- tronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis.
  • Page 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 22. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
  • Page 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
  • Page 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Center, depend- ing on your preference.
  • Page 41 Accessing Blink Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 38 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to access blink codes (failure codes) from the EFI mod- ule.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Blink Code Descriptions Blink Failure Description Code No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground...

  • Page 43: Operation

    Break-In Period The break-in period for your new POLARIS RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break- in period.
  • Page 44 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 65. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

  • Page 45: Operation

    Indicator lights/switches Ensure operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced...

  • Page 46: Starting Engine

    OPERATION Starting Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Apply the brakes. Place the transmission in PARK. 4. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START.

  • Page 47: Driving Procedure

    OPERATION Driving Procedure 1. Wear a helmet and eye protection. 2. Sit in the driver's seat and fasten the seat belt. 3. Start the engine and allow it to warm up. 4. Always use the cab nets while riding in this vehicle. 5.

  • Page 48: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 41. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

  • Page 49: Driving On Slippery Surfaces

    OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.

  • Page 50: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these pre- cautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 15° maximum 4. Always check the ter- rain carefully before ascending any hill. 5.

  • Page 51: Driving Downhill

    OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

  • Page 52: Driving Through Water

    OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service.

  • Page 53: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.

  • Page 54: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 55: Parking On An Incline

    OPERATION Parking the Vehicle 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 56: 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: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
  • Page 57 OPERATION 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. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

  • Page 58: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 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. Place the transmission in PARK. 4. Dismount the vehicle. 5.

  • Page 59: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when tow- ing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket. 2.
  • Page 60 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 61: 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 62: 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 quali- fied to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 63: 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 119.

  • Page 64: Maintenance Chart Key

    E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a n could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

  • Page 65: Maintenance

    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 66 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 67: Lubrication Recommendations

    See page 86. Main Gearcase Oil Premium AGL Synthetic See page 69. (Transmission) Gearcase Lube Front Gearcase Oil Demand Drive Plus Fluid See page 70. Front Prop Shaft Yoke POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum).

  • Page 68: Engine Oil

    Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil Recommendations POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil. See page 106 for the part numbers of POLARIS products.

  • Page 69: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. See page 64 for oil recom- mendations. Oil Check The oil tank is located under the seat. 1. Position the vehicle on a level surface.

  • Page 70: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface.
  • Page 71 MAINTENANCE Engine Oil Oil and Filter Change 11. Reattach the oil line. 12. Place shop towels beneath the oil filter. Using an oil fil- ter wrench, turn the filter counterclockwise to remove 13. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase.

  • Page 72: Specifications

    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 73: Polaris Products

    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 on the side of the gearcase.
  • Page 74 Refer to the Gearcase Specifications Chart on page 68 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 75 MAINTENANCE Gearcases Front Gearcase Oil Change 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's side. 3. Remove the fill plug. 4. Place a drain pan under the drain plug on the bottom right-hand side.

  • Page 76: Spark Plugs

    Refer to the specifications section beginning on page 104 for the recom- mended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark Plug Gap/Torque Model Electrode Gap...
  • Page 77 MAINTENANCE Spark Plugs Spark Plug Inspection 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. The tip should not be white.

  • Page 78: 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 products.

  • Page 79: Radiator And Cooling Fan

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

  • Page 80: 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 59. 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 81 • 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 82: 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. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.

  • Page 83: 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 84: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Service the air filter more fre- quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.
  • Page 85 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 86: Spark Arrestor

    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 87 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plug located on the bottom of the muf- fler. 2. Place the transmission in Clean-Out PARK. Plug 3. Start the engine. 4.

  • Page 88: 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 89: 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 90: 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 25. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 91: Brake Inspection

    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. Spring Adjustment Adjust the front and rear shock absorber...

  • Page 92: Tire Tread Depth

    MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

  • Page 93: 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. 3. Attach the wheel nuts and washers and finger tighten.

  • Page 94: Headlight Lamp Replacement

    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. Always make sure lights are adjusted properly for best visibility. 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.

  • Page 95: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 8" (20 cm) 25 ft. (7.6 m) 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 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 97: Battery Removal

    MAINTENANCE Battery Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1.

  • Page 98: 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 95 before installing the battery.

  • Page 99: Battery Storage

    See page 95. POLARIS recommends maintaining battery charge 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 100 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installa- tion of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 101 Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working prop- erly, please see your POLARIS dealer.

  • Page 102: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 103: Polishing The Vehicle

    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 104 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 105: Storage Tips

    98. 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 recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 106 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 107: Removal From Storage

    4. Check all the points listed in the Daily Pre-Ride Inspection section on page 41. 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 59.

  • Page 108: Specifications

    SPECIFICATIONS RANGER 500 EFI RANGER 500 EFI CREW Maximum Weight Capacity 1000 lbs. (454 kg) 1250 lbs. (567 kg) (includes weight of operator, pas- senger, cargo, accessories) Dry Weight 1055 lbs. (478.5 kg) 1300 lbs. (589.7 kg) Fuel Capacity 8.8 gal. (33.3 l) 8.8 gal.
  • Page 109 Hood Headlights 2 single beam, 50W, 2 single beam, 50W, quartz/halogen quartz/halogen Taillights 10 L.E.D. (.28W) 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) 10 L.E.D. (3.1W) Indicator Light 1.0 W 1.0 W Clutching See your POLARIS dealer for clutching specifications.

  • Page 110: Polaris Products

    Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel 2872073 Chain Lube, Aerosol (6.25 oz.) 2872348 Chain Lube, Aerosol (16 oz.) Additives / Miscellaneous 2871326 Carbon Clean Plus 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger...

  • Page 111: 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 112 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 113: Troubleshooting

    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 114 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 115: Declaration Of Conformity

    2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS...

  • Page 116: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 117 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materi- als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 118 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 Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 119 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
  • Page 120 How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 121 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 122 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 123: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 124 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 125: Maintenance Log

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

  • Page 126: Index

    INDEX Accessory Outlets ....22 Cleaning the Exhaust System . . . 82-83 Air Filter ..... 80 Cleaning the Spark Arrestor .

  • Page 127: Index

    INDEX Emissions Limited Warranty . 117-118 Fouled Plugs ....73 Engaging AWD....57 Freeplay Adjustment, Throttle .
  • Page 128 Lubrication Recommendations ..63 Polaris Products ....106 Polishing the Vehicle... . . 99 Pre-Ride Inspection .
  • Page 129 INDEX Spark Plug Gap ....72 Tachometer ....33, 35 Spark Plug Inspection .

This manual is also suitable for:

2011 ranger 500 efi crew2011 ranger 500 efi 4x4

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