Owners Manual
Page 5
...2009 RANGER 4X4 500 EFI Owner's Manual P/N 9921868 2 Copyright 2008 Polaris Sales Inc. Any reprinting or reuse of the depictions and/or procedures contained within this publication are registered trademarks of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle... and the information presented in part, is based on the latest product information at the time of Polaris Industries Inc. POLARIS and POLARIS THE WAY OUT are intended ...
...2009 RANGER 4X4 500 EFI Owner's Manual P/N 9921868 2 Copyright 2008 Polaris Sales Inc. Any reprinting or reuse of the depictions and/or procedures contained within this publication are registered trademarks of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle... and the information presented in part, is based on the latest product information at the time of Polaris Industries Inc. POLARIS and POLARIS THE WAY OUT are intended ...
Owners Manual
Page 16
... the vehicle for the safety of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with any other modifications to provide safe operation when used as directed. Polaris RANGERs are concerned for these purposes. Operator Safety WARNING SAFETY Make sure your RANGER is designed. The warranty on the vehicle. 13 Therefore, we strongly recommend that increase its speed or power. Failure of the vehicle, or...
... the vehicle for the safety of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with any other modifications to provide safe operation when used as directed. Polaris RANGERs are concerned for these purposes. Operator Safety WARNING SAFETY Make sure your RANGER is designed. The warranty on the vehicle. 13 Therefore, we strongly recommend that increase its speed or power. Failure of the vehicle, or...
Owners Manual
Page 28
... gear is intended for the RANGER. Always shift when the vehicle is stationary and the engine is important to the desired gear. Indicator Lights Brakes FEATURES AND CONTROLS Low Gear (if equipped) The indicator light panel is located on hardpacked surfaces with light loads. Reverse Gear High Temperature Neutral Gear High Gear Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for use on the console...
... gear is intended for the RANGER. Always shift when the vehicle is stationary and the engine is important to the desired gear. Indicator Lights Brakes FEATURES AND CONTROLS Low Gear (if equipped) The indicator light panel is located on hardpacked surfaces with light loads. Reverse Gear High Temperature Neutral Gear High Gear Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for use on the console...
Owners Manual
Page 29
... the electric starter. FEATURES AND CONTROLS Switches Light Switch AWD/Differential Switch Ignition Switch Ignition Switch The ignition switch is off , except Acc, 12V. Electrical circuits are off . Electrical circuits are on. WARNING Leaving the keys in the ignition can be removed from the switch when it is not in the OFF position. Turn the key to the START position to the ON position when released. The key can be used. Always remove the ignition key when the vehicle is...
... the electric starter. FEATURES AND CONTROLS Switches Light Switch AWD/Differential Switch Ignition Switch Ignition Switch The ignition switch is off , except Acc, 12V. Electrical circuits are off . Electrical circuits are on. WARNING Leaving the keys in the ignition can be removed from the switch when it is not in the OFF position. Turn the key to the START position to the ON position when released. The key can be used. Always remove the ignition key when the vehicle is...
Owners Manual
Page 30
... Wheel Drive (AWD). ON Switches FEATURES AND CONTROLS 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). See page 51 for AWD operating instructions. OFF AWD 2WD OFF 27 See page 52 for Differential Lock operating instructions. This mode of the switch to unlock the differential and allow the rear drive wheels to turf driving or when active traction is not needed. Light Switch The ignition switch key...
... Wheel Drive (AWD). ON Switches FEATURES AND CONTROLS 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). See page 51 for AWD operating instructions. OFF AWD 2WD OFF 27 See page 52 for Differential Lock operating instructions. This mode of the switch to unlock the differential and allow the rear drive wheels to turf driving or when active traction is not needed. Light Switch The ignition switch key...
Owners Manual
Page 36
... high speed operation during the break-in period as needed to maintain the oil level in period, change both the oil and the filter at sustained idle. 5. Vary throttle positions. Pull only light loads. Fill the fuel tank with vehicle operation and handling. 4. See page 34. 6. Pull only light loads. 7. Inspect and adjust park brake cable tension after the first 25 hours of the clutches and drive belt...
... high speed operation during the break-in period as needed to maintain the oil level in period, change both the oil and the filter at sustained idle. 5. Vary throttle positions. Pull only light loads. Fill the fuel tank with vehicle operation and handling. 4. See page 34. 6. Pull only light loads. 7. Inspect and adjust park brake cable tension after the first 25 hours of the clutches and drive belt...
Owners Manual
Page 49
... alter vehicle handling and may cause loss of control or brake instability, which could result in loss of control of the vehicle. Always attach the tow load to maintain stable driving conditions. Avoid terrain or situations that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. Stability and maneuverability may require backing downhill. Vehicle speed should...
... alter vehicle handling and may cause loss of control or brake instability, which could result in loss of control of the vehicle. Always attach the tow load to maintain stable driving conditions. Avoid terrain or situations that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. Stability and maneuverability may require backing downhill. Vehicle speed should...
Owners Manual
Page 50
Never exceed the following capacities. Passengers must always ride in the cab with passengers in the cargo box can result in the cargo box. Always read and understand the load distribution warnings listed on the warning labels. Model RANGER 4X4 500 EFI Maximum Capacities (Level Ground) 1500 lbs. (681 kg) Cargo Box 1000 lbs. (454 kg) WARNING Driving with seat belts fastened securely. 47 Never allow passengers to carry or tow specific capacities. Hauling Cargo OPERATION The RANGER has been designed to ride in severe injury or death.
Never exceed the following capacities. Passengers must always ride in the cab with passengers in the cargo box can result in the cargo box. Always read and understand the load distribution warnings listed on the warning labels. Model RANGER 4X4 500 EFI Maximum Capacities (Level Ground) 1500 lbs. (681 kg) Cargo Box 1000 lbs. (454 kg) WARNING Driving with seat belts fastened securely. 47 Never allow passengers to carry or tow specific capacities. Hauling Cargo OPERATION The RANGER has been designed to ride in severe injury or death.
Owners Manual
Page 52
... a trailer to the trailer hitch bracket only. See the towing capacity chart below and the specifications charts beginning on a grade steeper than the recommended weight for the vehicle. Model RANGER 4X4 500 EFI Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) Belt Life To extend belt life...
... a trailer to the trailer hitch bracket only. See the towing capacity chart below and the specifications charts beginning on a grade steeper than the recommended weight for the vehicle. Model RANGER 4X4 500 EFI Total Towed Load Weight (Level Ground) 1500 lbs. (681 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) Belt Life To extend belt life...
Owners Manual
Page 55
... AWD. This condition causes increased steering effort and some vehicle speed restriction. Initially, the vehicle's electronic system will automatically disengage. When the rear wheels regain traction, the front gearcase will not enable the AWD until the AWD switch is below 3100. NOTICE Switching to the length of time the vehicle may cause severe drive shaft and clutch damage. Stop the vehicle. 2. OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle...
... AWD. This condition causes increased steering effort and some vehicle speed restriction. Initially, the vehicle's electronic system will automatically disengage. When the rear wheels regain traction, the front gearcase will not enable the AWD until the AWD switch is below 3100. NOTICE Switching to the length of time the vehicle may cause severe drive shaft and clutch damage. Stop the vehicle. 2. OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle...
Owners Manual
Page 59
... X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment E tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 56 Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to severe use. change yearly Inspect level; change coolant...
... X Rear suspension Tires X Brake fluid level X Brake pedal travel Brake system Wheels/fasteners Frame fasteners X Engine oil level X Air filter, pre-filter E X Air box sediment E tube Coolant (if applicable) Headlamp/tail lamp X Air filter, E main element X Brake pad wear Q Battery X Front Gearcase Oil (if equipped) X Middle Gearcase Oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Perform these services. 56 Q Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to severe use. change yearly Inspect level; change coolant...
Owners Manual
Page 61
... grease to connectors subjected to severe use. Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Q Auxiliary brake (if X equipped) Headlight aim X Perform these services. 58 clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, pump, throttle body; replace lines every 2 years Replace yearly Inspect; Inspect; replace worn parts Inspect; X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E Q Ignition timing X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12 M 12 M 24...
... grease to connectors subjected to severe use. Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Q Auxiliary brake (if X equipped) Headlight aim X Perform these services. 58 clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, pump, throttle body; replace lines every 2 years Replace yearly Inspect; Inspect; replace worn parts Inspect; X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E Q Ignition timing X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12 M 12 M 24...
Owners Manual
Page 72
... exhaust system and engine can result in serious engine damage. Wear protective gloves when removing a spark plug for correct color. Refer to the specifications section beginning on page 106. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is indicative of engine operation. Immediately check the spark plug for inspection. 69 Always use Polaris-recommended spark plugs. Spark Plug Gap/Torque Model RANGER 4X4 500 EFI Electrode...
... exhaust system and engine can result in serious engine damage. Wear protective gloves when removing a spark plug for correct color. Refer to the specifications section beginning on page 106. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is indicative of engine operation. Immediately check the spark plug for inspection. 69 Always use Polaris-recommended spark plugs. Spark Plug Gap/Torque Model RANGER 4X4 500 EFI Electrode...
Owners Manual
Page 95
... the weight of the headlight beam should be aimed 8" (20 cm) below the mark placed on the seat while performing this step. 5. Loosen the screw, adjust the headlight, and tighten the screw. 7. Repeat steps 4-6 until the lamp is properly adjusted. 92 Start the engine. Observe the headlight aim. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Apply the brakes. Turn on the...
... the weight of the headlight beam should be aimed 8" (20 cm) below the mark placed on the seat while performing this step. 5. Loosen the screw, adjust the headlight, and tighten the screw. 7. Repeat steps 4-6 until the lamp is properly adjusted. 92 Start the engine. Observe the headlight aim. MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Apply the brakes. Turn on the...
Owners Manual
Page 109
...) 1000 lbs. (454 kg) 4 valve 4 stroke single cylinder with counter balance 499 cc 92 x 75 250 W 10.2:1 Electric Electronic Fuel Injection CDI 30° @5000 RPM NGK BKR5E Dual A-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel 106 SPECIFICATIONS RANGER 4X4 500 EFI Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min.
...) 1000 lbs. (454 kg) 4 valve 4 stroke single cylinder with counter balance 499 cc 92 x 75 250 W 10.2:1 Electric Electronic Fuel Injection CDI 30° @5000 RPM NGK BKR5E Dual A-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel 106 SPECIFICATIONS RANGER 4X4 500 EFI Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min.
Owners Manual
Page 110
... Lever (console) 8.71:1 7.91:1 3.85:1 3.818:1 3.70:1 25 x 10 - 12 25 x 11 - 12 8-12 psi (69 KPa) 8-12 psi (69 KPa) Foot Activated, 4 wheel hydraulic disc Hand activated, mechanical 2 single beam, 50W, quartz/halogen 10 L.E.D. (.28W) 10 L.E.D. (3.1W) 1.0 W NOTE: See your Polaris dealer for clutching specifications. 107 Low Gear Reduction - SPECIFICATIONS RANGER 4X4 500 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction...
... Lever (console) 8.71:1 7.91:1 3.85:1 3.818:1 3.70:1 25 x 10 - 12 25 x 11 - 12 8-12 psi (69 KPa) 8-12 psi (69 KPa) Foot Activated, 4 wheel hydraulic disc Hand activated, mechanical 2 single beam, 50W, quartz/halogen 10 L.E.D. (.28W) 10 L.E.D. (3.1W) 1.0 W NOTE: See your Polaris dealer for clutching specifications. 107 Low Gear Reduction - SPECIFICATIONS RANGER 4X4 500 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction...
Owners Manual
Page 118
...the country where your vehicle to another country, be covered by an authorized Polaris dealer. This policy does not apply to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to Safety Recalls. You may not ...warranty coverage will continue to be sure to Get Service In the Country where your vehicle was purchased, you have any kind. (Vehicles registered to perform the warranty repair. If You Move: If you move to Polaris Industries in which the vehicle was purchased, and you purchase a Polaris product from Polaris...
...the country where your vehicle to another country, be covered by an authorized Polaris dealer. This policy does not apply to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to Safety Recalls. You may not ...warranty coverage will continue to be sure to Get Service In the Country where your vehicle was purchased, you have any kind. (Vehicles registered to perform the warranty repair. If You Move: If you move to Polaris Industries in which the vehicle was purchased, and you purchase a Polaris product from Polaris...
Owners Manual
Page 123
INDEX A Accessory Outlets ...24 Adding Coolant ...71 Adjustments Headlight Beam ...92 Park Brake ...86 Suspension ...87 Shock Spring ...87 Throttle Freeplay ...83 Age Restrictions...8 Air Filter ...78 Air Filter Cleaning...78 All Wheel Drive...52 All Wheel Drive Lock Switch ...27 Arrestor, Spark, Warning...80-81 Auxiliary Outlets ...24 AWD ...52 AWD/Differential Lock Switch...27 Axle Nut Torque ...88 C Capacity, Weight ...47 Cargo ...46-47 Cargo Box, Dumping...48 Changing Coolant ...71 Changing Gears ...25 Changing Oil Engine ...62 Front Gearcase...67 Rear Gearcase ...68 Transmission/Main ...
INDEX A Accessory Outlets ...24 Adding Coolant ...71 Adjustments Headlight Beam ...92 Park Brake ...86 Suspension ...87 Shock Spring ...87 Throttle Freeplay ...83 Age Restrictions...8 Air Filter ...78 Air Filter Cleaning...78 All Wheel Drive...52 All Wheel Drive Lock Switch ...27 Arrestor, Spark, Warning...80-81 Auxiliary Outlets ...24 AWD ...52 AWD/Differential Lock Switch...27 Axle Nut Torque ...88 C Capacity, Weight ...47 Cargo ...46-47 Cargo Box, Dumping...48 Changing Coolant ...71 Changing Gears ...25 Changing Oil Engine ...62 Front Gearcase...67 Rear Gearcase ...68 Transmission/Main ...
Owners Manual
Page 124
... Headlight Lamp Replacement ...91 Hitch Bracket ...23 Hitch Weight...49 Hour Meter ...24 I Idle Speed ...Ignition Switch ...Indicator Light Replacement ...Indicator Lights...Inspection Axle Nuts ...Brakes ...Cylinder Head/Base Fastener . . Park Brake ...Pre-Ride ...Seat Belts ...Throttle Freeplay ...Wheel Nuts ...Installation, Battery...Installation, Wheels ...Interference, Electromagnetic...83 26 93 25 88 85 83 85 34 77 82 88 96 90 53 F Fan, Cooling ...72 Filling the Battery (Conventional) . . 97 Filter Care During Storage ...103 Filter Change...62 Filter Cleaning, Air ...78 Filter...
... Headlight Lamp Replacement ...91 Hitch Bracket ...23 Hitch Weight...49 Hour Meter ...24 I Idle Speed ...Ignition Switch ...Indicator Light Replacement ...Indicator Lights...Inspection Axle Nuts ...Brakes ...Cylinder Head/Base Fastener . . Park Brake ...Pre-Ride ...Seat Belts ...Throttle Freeplay ...Wheel Nuts ...Installation, Battery...Installation, Wheels ...Interference, Electromagnetic...83 26 93 25 88 85 83 85 34 77 82 88 96 90 53 F Fan, Cooling ...72 Filling the Battery (Conventional) . . 97 Filter Care During Storage ...103 Filter Change...62 Filter Cleaning, Air ...78 Filter...
Owners Manual
Page 126
...-81 Spark Plugs Condition ...70 Gap ...69 Removal ...70 Torque ...69 Fouled ...70 Specifications ...106-107 Specifications, Gearcase ...65 Speed, Idle ...83 Speed, Towing ...49 Stabilizing the Fuel ...103 Starting the Engine ...35 Steering Wheel, Adjustment ...31 Stopping the Engine ...36 Storage Area...104 Battery...97 Covers ...104 Fluid Levels ...104 Inspection ...103 Lubrication ...103 Oil and Filter ...103 Removal ...105 Suspension Adjustment...87 Switches AWD Switch...27 Differential Lock Switch ...27 Ignition Switch ...26 Light Switch ...27 Synthetic Oil ...60 T Throttle Freeplay...
...-81 Spark Plugs Condition ...70 Gap ...69 Removal ...70 Torque ...69 Fouled ...70 Specifications ...106-107 Specifications, Gearcase ...65 Speed, Idle ...83 Speed, Towing ...49 Stabilizing the Fuel ...103 Starting the Engine ...35 Steering Wheel, Adjustment ...31 Stopping the Engine ...36 Storage Area...104 Battery...97 Covers ...104 Fluid Levels ...104 Inspection ...103 Lubrication ...103 Oil and Filter ...103 Removal ...105 Suspension Adjustment...87 Switches AWD Switch...27 Differential Lock Switch ...27 Ignition Switch ...26 Light Switch ...27 Synthetic Oil ...60 T Throttle Freeplay...