Polaris 4X4 500 EFI manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e p roudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excell ence for a ll[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS V ehicle Identification Numbers . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F eatures and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Emission Control Systems . . . . . . . . . . . . . . . 51 M[...]

4 VEHICLE IDENTIFICA TION NUMBERS Record your vehicle's identificatio n numbers and key numb er 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 k ey number) and mating it with o ne of your existing keys. The ignition switch must be rep[...]

5 SAFETY Safety Decals and Locations W arning de cals have been placed on the vehicle fo r your protection. Read and follow the instructions of the decals on the vehicle carefully . If any of the decals depicted in this ma nual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle . If any deca[...]

6 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. T o prevent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serio us injury or d[...]

7 SAFETY Safety Decals and Locations Shift Caution CAUTION T o avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary W arning WARNING Improper vehicle use can result in SEVERE INJURY or DEA TH. NEVER: • Operate on public roads. A collision can occur with a another vehicle. • Carry more than two passengers, [...]

8 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger in this vehicle. Know Y our V ehicle As the operator of the vehicle, y o u are responsible for your p ersonal safety , the safety of others, and th e prot[...]

9 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

10 SAFETY Operator Safety • Read this manual and all labels careful ly . Follow the operating procedures described. • Never allow anyone without a valid driver's license to operate this vehicle. • Minimum age recommendation for passengers is five years old. Passengers under five ye ars of age re quire special restraints which are not ava[...]

11 SAFETY Operator Safety • Always follow proper procedures for turning as described in this manual. Practice turning at slow spee ds 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 vehicl[...]

12 SAFETY Operator Safety • Never modify this vehicle throug h improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo sh ould be properly distributed and securely attached. Reduce speed and fol- low the instructions in this manu al for hauling cargo or pulling a trailer . Allow a greater dis[...]

13 SAFETY Operator Safety Equipment Modifications W e are co ncerned for the safety of our customers and for the general public. Therefore, we strongly reco mmend 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 fo r these purposes. An[...]

14 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Stalling, rolling b ackwards while climbing a hill WHA T CAN HAPPEN V ehicle overturn HOW TO A VOID 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 en[...]

15 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this vehicle wit hout prop er instruction WHA T CAN HAPPEN Loss of control, accident HOW TO A VOID THE HAZARD The risk of an accident is greatly increased if th e operator does not know how to opera te the vehicle properly i n different situations and on different types of terrain. Al[...]

16 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Operating this vehicle after consum ing alcohol or drugs WHA T CAN HAPPEN Could seriously a ffect your judgment. Could cause you to react more slowly . Could affect your balance and perception. Could result in an accident. HOW TO A VOID THE HAZARD Driving a RANGER requires your full attention. [...]

17 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD Attempting jumps and other stunts WHA T CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO A VOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WAR N I N G POTENTIAL HAZARD Operating on frozen b odies of water . WHA T CAN HAPPEN Severe injury or dea[...]

18 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD F ailure to inspect the vehicle before ope rating F ailure to properly maintain the vehicle WHA T CAN HAPPEN Accident, equipment damage HOW TO A VOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow the inspection and mainte[...]

19 SAFETY Operator Safety WAR N I N G POTENTIAL HAZARD F ailure to follow the minimu m age recommendations fo r this vehicle WHA T CAN HAPPEN Serious injury or death (the child or others) HOW TO A VOID THE HAZARD Only persons with a valid driver's license shou ld operate a Polaris RANGER . Even though a child may be within the age group for wh[...]

20 SAFETY Operator Safety WAR N I N G Leaving the keys in the ignition can lea d to unauthorized use of the vehicle resulting in serious injury or death. Always re move the ignition key when the vehicle is not in u se. WAR N I N G After any overturn or accident, have a qualified service dea ler inspect the entire vehicle for possible damage, includ[...]

21 SAFETY F uel Safety WAR N I N G Gasoline is highly flammable and is explosive under certa in conditions. Always exercise extreme caution w henever handling gasoli ne. Always stop the engine when refu eling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refu eling area or where ga [...]

22 FEA TURES AND CONTROLS Component Locations Some Polaris vehicles are equipped wi th special feature s such as the cab frame. Not all models come with all fe atures. Refer to the specifications section beginning on page 100. Cab F rame (if Equipped ) Console Steering Wheel Hip Bar Seat Storage Box (under driver’s sea t) Cargo Box Seat Belt Batt[...]

23 FEA TURES AND CONTROLS Component Locations Headlights Hood Hold-Down Strap F ront Bumper/Brush Guar d Radiator (if equipped )[...]

24 FEA TURES AND CONTROLS Component Locations T a ilgate Latch Release T a illights Air Box Receiver Hitch CV Boot/Rear Caliper Muffler (Spark Arrestor) T aillights T ailgate[...]

25 FEA TURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is locate d on the console. See page 28. T railer Hitch Bracket This vehicle is equipped with a recei ver hitch bracket for a trailer hitch. T railer towing equipment is no t supplied with this vehicle. T o avoid injury and pro perty damage, always heed the war[...]

26 FEA TURES 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. Fu e l C a p / Fu e l G a u g e The fuel tank filler cap is located on[...]

27 FEA TURES AND CONTROLS Seat Belts The RANGER is equipped with lap- style seat belts for the operator and passenger . T o wear the seat belt properly , follow this procedure: 1. Place the belt across your lap as low on your hips as possible. Make sure that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Releas[...]

28 FEA TURES AND CONTROLS Console Indicator Lights AWD/Differential Switch Cup Holder Cup Holder Storage Compartment (with lid) 12V Accessory Outlet Storage Tr a y Ignition Switch Storage Box Light Switch Gear Selector (Shifter)[...]

29 FEA TURES AND CONTROLS 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 ha rd- packed surfaces with light loads. T o change gears, stop the vehicle, and with the engi ne idling, move the lever to the desired gear . Do not attempt to shift ge[...]

30 FEA TURES AND CONTROLS Brake P edal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle P edal Push the pedal down to increase engine s peed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before start- ing the engin[...]

31 FEA TURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-positio n, key-operated switch. The key can be removed from the switch wh en it is in the OFF position. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has th ree positions: high beam, low beam and off. A[...]

32 OPERA TION V ehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it take s to use the first two tanks ful l of gasoline. No single action on your part is as important as a proper break- in period. Careful treatm ent of a new engine will result in more efficient performance an[...]

33 OPERA TION Pre-Ride Inspection WAR N I N G If a proper inspection is not done befor e ea ch use, severe i njury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition. Item Remarks P age Brake system/pedal travel En sure proper operation 30 79 Brake fluid Ensure proper level 79 F ront[...]

34 OPERA TION Starting Engine 1. Sit in the driver's seat and fasten the seat belt. 2. Engage the park brake. 3. Shift the transmission to neutral. 4. Apply the brake s. NOTE: Do not pre ss the throttle peda l while starting the en gine. 5. T urn the ignition key past the ON/RUN position to ST AR T . Engage the starter for a maximum of five se[...]

35 OPERA TION Stopping the Engine 1. Release the throttle pedal complete ly and brake to a complete stop. 2. T urn the engine off. 3. Engage the park brake. Braking 1. Release the throttle pedal completely . 2. Press on the brake pedal evenly and firmly . NOTE: Practice starting and stopping (usin g the brakes) until you're familia r with the [...]

36 OPERA TION 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 surroun dings and determine your path of travel. 4. Release the park brake. 5. Keeping both hands on the s[...]

37 OPERA TION 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 slidin g. Under these con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertne ss, reading the trail and avoi[...]

38 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void steep hills (15 ° maximum). 3. Keep both feet on the floor . 4. Procee d at a steady rate of speed and throttle opening. WAR N I N G Climbing hills imprope rly can cause loss of contro l or vehicle overturn. [...]

39 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brake s slightly to aid in slowing. WAR N I N G Crossing hillsides or turning on hills c an result in loss of control or vehicl e overturn, resulting in sev[...]

40 OPERA TION Driving Safely Driving Through W ater Yo u r P o l a r i s RANGER can operate through water up to a maximum recommended de pth equal to the floor- boards. Follow these procedures when oper- ating through water: 1. Always determine water depths and current before entering. 2. Choose a crossing where both banks have gradual inclines. 3.[...]

41 OPERA TION Driving Safely Driving Over Obstacles Be alert! Look ahead and lear n to re ad the terrain you're traveling on. W atch for hazards such as logs, rocks and low hanging branches. WAR N I N G Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obstacles are immedia tely visible[...]

42 OPERA TION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the brak es lightly for stopping. 3. A void tu rning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always inspect left an d right fields of vision before backing. WAR[...]

43 OPERA TION Driving Safely P arking on an Incline A void parking o n an incline if poss ible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear . 2. Engage the park brake. 3. T urn the engine off. 4. Block the rear wheels on the downhill side. WAR N I N G A rolling vehicle can ca use property damage and serious[...]

44 OPERA TION Driving Safely Hauling Cargo WAR N I N G Hauling cargo imprope rly can alter vehicle handling and may cause loss of control or brake instability , whi ch can result in serious injury or death. Always follow these p recautions when ha uling cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO . Always load [...]

45 OPERA TION 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 Max imum Capacities (Level Ground) Cargo B ox RANGER 4X4 500 EFI 1500 lbs. (681 kg) 1000 lbs. (454 kg) WAR N[...]

46 OPERA TION Driving Safely Dumping the Cargo Box 1. Select a level site to dump the car go box. Do not attempt to dump or unload the vehicle while parke d on an incline. 2. Engage the park brake. 3. Dismount the vehicle. 4. Ensure that the cargo is positioned evenly or toward the front of the carg o box. 5. Release the tailgate by pulling up on t[...]

47 OPERA TION Driving Safely T owing Loads Belt Life T o extend belt life, use the lowest gear po ssible when hauling or towing heavy cargo. WAR N I N G T owing improperly can alter vehicle handling and may cause l oss of control or brake instability , which can result in serio us injury or death. Always follow these precautions when towing: Never [...]

48 OPERA TION Driving Safely P arking the V ehicle 1. Stop the vehicle on a level surface. 2. T urn the engine off. 3. Engage the park brake. 4. Remove the ignition switch key to prevent unauthorized use. WAR N I N G A rolling vehicle can cause property damage and serious injury . Always engage the park brake after stopping the engine. WAR N I N G [...]

49 OPERA TION Differential Operation Modes The 4X4 rear axle is equipped with a lockab le differe n tial that allows the operato r to choose betwe en an open dif ferential or a closed dif feren- tial. AWD Press the top of the rocker switch to engage All Wheel Drive (A WD). When in A WD, the rear wheels rotate at the same speed. The front wheels als[...]

50 OPERA TION All Wheel Drive (A WD) The illuminated amber A WD switch indicates that the vehi- cle is in A WD. When the A WD 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. There is no limit to the length of t[...]

51 EMIS SION 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. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that wa s tested and qual[...]

52 MAINTENANCE P eriodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

53 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Q Have an authorized Polaris dealer perform these services. WAR N I N G Improperly performing the p rocedures marked with a Q coul d result in compone[...]

54 MAINTENANCE P eriodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Cale[...]

55 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Engine breather filter (if equipped) 25 H Monthly - In[...]

56 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q E F uel system 100 H 12 M - Check for leaks at tank cap,[...]

57 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 5 2, or more often under severe use, such as wet or dusty cond itions. Items not listed in the chart should be lubricated at the general lubrication interval. . Item Lube Method Engine Oil Po[...]

58 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Ch art beginning on page 5 2. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Pola ris 4-cycle engines. It'[...]

59 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginn ing on page 52. W e recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil tank is located under the seat. 1. Position the vehicle on a level surface. 2. Apply the brakes. Start the engine a[...]

60 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engi ne. 3. Clean the area[...]

61 MAINTENANCE Engine Oil Oil and Filter Change 10. Reattach the oil line. 1 1. Place shop towels beneath the oil filter . Using an oil fil- ter wrench, turn the filter counterclockwise to remove it. 12. Using a clean dry cloth, clean the filter sealing sur- face on the crankcase. 13. Lubricate the gasket on the new filter with a film of new engine[...]

62 MAINTENANCE 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 of f the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line&apos[...]

63 MAINTENANCE Gearcases Gearcase Specification Chart T ransmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 52. Maintain the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, [...]

64 MAINTENANCE Gearcases T ransmission (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 pla te. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Drain the oil. 4. W ipe the magnetic end of the drain plug clean[...]

65 MAINTENANCE Gearcases F ront Gearcase Always check and change the front g earcase oil at the intervals outlined in the Periodic Maintenance Chart be ginning on page 52. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specific ations Chart on page 63 for recommended lubricants, capacities and torque[...]

66 MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Refer to the Gearcase Specific ations Chart on page 63 for recommended lubricants, capacities and torque spec ifications. See page 102 for the part numbers of Po laris lubrication pro[...]

67 MAINTENANCE Spark Plugs Spark Plug Gap/T orque Spark plug condition is indicative of engine operation. The spark plug firing end condi tion should be read after the engine is warmed up and the vehicle is driven at higher speed s. Immediately check the spark plug for correct color . See page 68. CA UTION Using non-recommended spark plugs can resu[...]

68 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray , ta n 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 no t be white. A white insulator tip in dicates overh[...]

69 MAINTENANCE Cooling System Operation The engine coolant level is controlled or mainta ined by the recovery system. The recovery system componen ts are the overflow bottle, radia- tor filler neck, radiator pr essure cap and connecting hose. As coolant operating temperature increases, the expa nding (heated) excess coolant is forced out of the rad[...]

70 MAINTENANCE Cooling System Radiator and Cooling F an Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 52. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiat or or behind the cooling fan. Inter-[...]

71 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 52. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiat or or behind the cooling fan. Inter- fe[...]

72 MAINTENANCE P olaris V ariable T ran smission (PVT) System When T o Use Low Ra nge vs. High Range Belt slip is responsible for creating excessive heat that destroys belts , wears clutch components and causes ou ter clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT componen ts (belt, cover ,[...]

73 MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys- tem. Use the following instructions to dry it out before operating. 1. Loosen the bottom screws that secu re the clutch cover . Allow the water to drain. Tighten the screws. 2. Apply the brakes. Start the engine. Enga ge the park brak e. Shift [...]

74 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginn ing on page 52. 1. Lift the car go box to access the air box. 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter . 4. Do[...]

75 MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the car go box and locate the air box. 2. Follow the right-hand breather line out the side of the air box an d 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 clogging. Replace as needed. 4. Chec[...]

76 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge accumulated carbon from the exha ust pipe. 1. Remove the arrestor clean-out plugs located on the bottom of the muffler . 2. Shift the transmission to neutral. Apply the brakes. Start the engine. 3. Purge accumulated carbon from the system by momentarily rev- ving the [...]

77 MAINTENANCE Throttle System Throttle F reeplay If the throttle pedal has excessive play due to c able stretch or mis- adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully . If the throttle pedal has no freeplay , the throttle may be hard to control, and the idle speed may be[...]

78 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Polaris dealer for adjustment. Throttle F reeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster . 3. Squeeze the end of the rub- ber boot and sli de it far enough to ex[...]

79 MAINTENANCE Brakes The front and rear brakes are hydra ulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30. Brake Fluid Inspect the brake syste m rou- tinely . Inspect the level of the brake fluid before each opera- tion. Change the brake fluid every two years and any time the fluid becomes contaminated, the fl[...]

80 MAINTENANCE Brakes Brake Inspection 1. Check the br ake 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 . 5. Change pads wh en worn to 3/64" (1 mm). P ark Brake Inspecti[...]

81 MAINTENANCE Steering Wheel Inspection Check the steering wheel for s pecifie d freeplay and smooth op eration at the intervals outlined in the Period ic Maintenance Chart beginning on page 52. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0 " (20-25 mm) of freep[...]

82 MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before ea ch use of the vehicle. 1. Push the latch plate into the buck le until it clicks. The latch plate must slide smoothly in to the buckle. A click indicates that it's securely latched. 2. Push the red button in the middle of the buckle to make sure it releases fr[...]

83 MAINTENANCE Tires Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut T orque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or the lug nut. WAR N I N G Operating your vehi[...]

84 MAINTENANCE Tires Wheel Removal 1. Stop the engine. Place the transm ission in gear . Engage the park brake. 2. Loosen the wheel nuts slightly . 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in gear . 2. Engage t[...]

85 MAINTENANCE Lights When servicing a halog en 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. Headlight Lamp Replacement 1. Open the hood. 2. Unplug the headlamp from the wiring harness. Be sure to pull on the co nnector , not on the wiring. 3. T ur[...]

86 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 floo r to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. T urn on the headlights. 4. Observe the h[...]

87 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the console brake light comes on. Check the brake ligh t before each ride. 1. T urn the ignition switch to the ON position. 2. Depress the brake pedal. The brak e light should come on after about 10mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb. I[...]

88 MAINTENANCE Battery Y our 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 conne[...]

89 MAINTENANCE Battery Battery Removal 1. Open the hood. 2. On conventional batteries, remove the batte ry vent tube. 3. Disconnect the black (nega- tive) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery side- ways, which could spill elec- [...]

90 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 92 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batter y in the[...]

91 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to maintain a full charge. See page 92. NO[...]

92 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electrolyt e during charging. See page 89. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.270 o[...]

93 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery con dition before and 1-2 h ours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cur rent charger @ standard amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required[...]

94 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleaning [...]

95 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: • Wheel bearings • Radiator • T ransmission seals •B r [...]

96 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “lik e new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coasta l areas) are more susce ptible to corrosion if no t properly clean ed. [...]

97 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 94. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel S tabilizer . Follow the instructions on th e container for the rec ommended amount. NOTE: Carbon Cle[...]

98 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. T reat the fuel system with Pola ris Carbon Clean. Follow the instruc- tions on the container . Start the engine. Allow it to idl e for several minutes so the Carbon Clean re aches the injectors. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Syn- th[...]

99 MAINTENANCE Removal from Storage 1. Check the battery electrolyte leve l and char ge the battery if neces- sary . Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way . 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points li[...]

100 SPECIFICA TIONS RANGER 4X4 500 EFI Gross V ehicle W eight 2700 lbs. (1226 kg) Dry W eight 1 185 lbs. (537 kg) Overall Length 1 13 in. (282 cm) Overall W idth (box) 60 in. (152.4 cm) Overall W idth (tires) 58 in. (147.3 cm) Overall Height 75 in. (190.5 cm) Wheelbase 76 in. (193 cm) Cargo Box (L x W x H) 58 x 42 x 10 in. (147 x 106.7 x 25.4 cm) G[...]

101 SPECIFICA TIONS NOTE: See your Polaris dealer for clutchin g specifications. RANGER 4X4 500 EFI Lubrication System Dry Sump Engine Oil 0W/40 Driving System T ype PVT Shift T ype Single Lever (console) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.9:1 Gear Reduction - High 3.83:1 Drive Ratio - Front: 3.83:1 Drive Ratio - Final 3.70:1 T [...]

102 POL ARIS PRODUCTS Pa rt N u m b e r Description Engine Lubr icant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Pre mium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Pre mium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / T ransmission Lubricants 2873602 Pre mium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Pre mium AGL Synth[...]

103 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range. See wa rnings on page 38. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequently . See page 72. Insu[...]

104 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Loose electronic control box connections Insp[...]

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

106 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Insp ect, clean and/or replace spark p lug W orn or defective spark plug wires See your dealer Incorrect spark plug gap or hea[...]

107 WA RRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polari s also gives a one year lim ited warranty on the final drive chain for failure due to defects. This warr anty covers the parts and l[...]

108 W ARRANTY LIMIT A TIONS OF WARR ANTIES AND REMEDIE S ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY P ERIOD. POLARIS FUR THER DISCLAIMS AL L EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . [...]

109 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

110 W ARRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Off Road Utilit y V ehicle (ORUV) emissions limited warranty is in additi on to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the [...]

111 WA RRANTY California Emission Control W arranty Statement Y our W arranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2005 and later Lar ge Spark Ignition Engine ([...]

112 W ARRANTY California Emission Control W arranty Statement Owner's W arranty Responsibilities: • As the LSI engine owner , you are responsib le for the performance o f the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you reta in all receipt[...]

113 WA RRANTY California Emission Control W arranty Statement Emission-Related P arts Covered Under This W arranty (1) Fuel Metering System (i) Carburetor and internal pa rts (and/or pressure reg ulato r or fuel injection system) (ii) Air/fuel ratio feedback an d control system, if applicable (iii) Cold start enrichment system, i f applicable (iv) [...]

114 W ARRANTY California Emission Control W arranty Statement What is Not Covered Under This W arranty This warranty does not cover a ny emission-related part whic h malfunctions, fails or is damaged due to altera tions and/or modifications such as changing, adding or removing parts. When the LSI engine is being serviced un der warranty , POLARIS a[...]

115 WA RRANTY X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services Repair and Replacement of Emission-Related P arts It is recommended that only LSI en gine replacement parts, which have been authorized and app roved by POLARIS, should be [...]

116 MAINTENANCE L OG Use the following chart to r ecord periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

117 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

11 8 INDEX A Adding Coolant . . . . . . . . . . . . . . . . 69 Adjustment Headlight Beam . . . . . . . . . . . . 86 Park Brake . . . . . . . . . . . . . . . . 80 Rear Spring . . . . . . . . . . . . . . . 81 Rear Suspension . . . . . . . . . . . 81 Throttle Free play . . . . . . . . . . . 78 Age Restrictions . . . . . . . . . . . . . . . . . 8 Air F[...]

11 9 INDEX E Electromagnet ic Interference . . . . . . 51 Emission Control, Crankc ase . . . . . . 51 Emission Control, Exha ust . . . . . . . . 51 Emission Control, Noi se . . . . . . . . . . 51 Emissions Li mited Warranty . . . . . 110 Engine Fogging . . . . . . . . . . . . . . . . . 98 Engine Idle Spee d . . . . . . . . . . . . . . . 78 Engine O[...]

120 INDEX M Main Gearcase Lubrication . . . . . . . . . . . . . . . . 63 Oil Change . . . . . . . . . . . . . . . . 64 Oil Check . . . . . . . . . . . . . . . . . 63 Maintenance Log . . . . . . . . . . . 116-117 Maintenance, Periodic . . . . . . . . . 52-56 Modifications . . . . . . . . . . . . . . . . . . 13 N Noise Emissio n Control System . . . [...]

121 INDEX S Speed, Towing . . . . . . . . . . . . . . . . . 47 Spring, Rear, Adju stment . . . . . . . . . 81 Stabilizi ng the Fuel . . . . . . . . . . . . . . 97 Starting the Eng ine . . . . . . . . . . . . . . 34 Steering Wheel Inspe ction . . . . . . . . 81 Stopping the Engine . . . . . . . . . . . . . 35 Storage . . . . . . . . . . . . . . . . [...]