Owners Manual
Page 4
... the cab nets. avoid sharp turns or sudden braking. On public roads. Watch for your skills or the conditions. On paved surfaces - READ OWNER'S MANUAL. With more than ONE passenger on the CREW, or with more than 15 degrees 15 . Avoid sharp turns or turns while applying heavy throttle. Vehicle rollover could enter vehicle. Make sure passenger reads and understands all times. PMS 419 WARNING Improper vehicle use...
... the cab nets. avoid sharp turns or sudden braking. On public roads. Watch for your skills or the conditions. On paved surfaces - READ OWNER'S MANUAL. With more than ONE passenger on the CREW, or with more than 15 degrees 15 . Avoid sharp turns or turns while applying heavy throttle. Vehicle rollover could enter vehicle. Make sure passenger reads and understands all times. PMS 419 WARNING Improper vehicle use...
Owners Manual
Page 18
... speed and follow the instructions in this manual for braking. • Always place the transmission in this vehicle through improper installation or use of flame or sparks. Allow a greater distance for hauling cargo or pulling a trailer. Gasoline is well ventilated and free of any source of accessories. • Never exceed the stated load capacity for fuel safety warnings. • Always remove the ignition key...
... speed and follow the instructions in this manual for braking. • Always place the transmission in this vehicle through improper installation or use of flame or sparks. Allow a greater distance for hauling cargo or pulling a trailer. Gasoline is well ventilated and free of any source of accessories. • Never exceed the stated load capacity for fuel safety warnings. • Always remove the ignition key...
Owners Manual
Page 21
... the engine when refueling. • Remove flammable material containers from this product contains chemicals known to ) brakes, throttle and steering systems. Operating at Excessive Speeds Operating this vehicle at all inspection and maintenance procedures and schedules described in an enclosed area. Always keep hands and feet inside the vehicle at excessive speeds increases the operator's risk of losing control. SAFETY Operator Safety Cab Nets...
... the engine when refueling. • Remove flammable material containers from this product contains chemicals known to ) brakes, throttle and steering systems. Operating at Excessive Speeds Operating this vehicle at all inspection and maintenance procedures and schedules described in an enclosed area. Always keep hands and feet inside the vehicle at excessive speeds increases the operator's risk of losing control. SAFETY Operator Safety Cab Nets...
Owners Manual
Page 25
Trailer towing equipment is equipped with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 52-55. 21 FEATURES AND CONTROLS Component Locations Tailgate Latch Releases Tailgate Muffler Receiver (Spark Arrestor) Hitch CV Boot/Rear Caliper Trailer Hitch Bracket This vehicle is not supplied with a receiver hitch bracket for a trailer hitch.
Trailer towing equipment is equipped with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 52-55. 21 FEATURES AND CONTROLS Component Locations Tailgate Latch Releases Tailgate Muffler Receiver (Spark Arrestor) Hitch CV Boot/Rear Caliper Trailer Hitch Bracket This vehicle is not supplied with a receiver hitch bracket for a trailer hitch.
Owners Manual
Page 28
... can be used . Turn the key to the START position to the LIGHTS ON position after starting the engine. 24 Lights are off, except Acc, 12V. Lights are on. The key can be removed from the switch when it is off . Electrical circuits are off . Electrical circuits are on . Turn the key to engage the electric starter. FEATURES AND CONTROLS Switches Ignition Switch Light Switch AWD/Differential Switch Ignition Switch/Light Switch The ignition switch is a four-position, key-operated switch. Electrical equipment can be...
... can be used . Turn the key to the START position to the LIGHTS ON position after starting the engine. 24 Lights are off, except Acc, 12V. Lights are on. The key can be removed from the switch when it is off . Electrical circuits are off . Electrical circuits are on . Turn the key to engage the electric starter. FEATURES AND CONTROLS Switches Ignition Switch Light Switch AWD/Differential Switch Ignition Switch/Light Switch The ignition switch is a four-position, key-operated switch. Electrical equipment can be...
Owners Manual
Page 36
... the instrument cluster. AWD Indicator - Low Battery and Over Voltage - The segments of the fuel gauge show the level of fuel in the AWD position. 3. This indicator serves two purposes. Serious engine damage could result. 32 This warning usually indicates that the vehicle is operating at a higher RPM or recharge the battery to your Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is...
... the instrument cluster. AWD Indicator - Low Battery and Over Voltage - The segments of the fuel gauge show the level of fuel in the AWD position. 3. This indicator serves two purposes. Serious engine damage could result. 32 This warning usually indicates that the vehicle is operating at a higher RPM or recharge the battery to your Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is...
Owners Manual
Page 44
Fill the fuel tank with vehicle operation and handling. 4. Add the recommended oil as recommended. Select an open area that allows room to maintain the oil level in period. 40 Perform regular checks on fluid levels, controls and areas outlined on page 17. 2. Pull only light loads. 7. Avoid aggressive acceleration and high speed operation during the break-in of the clutches and drive belt will...
Fill the fuel tank with vehicle operation and handling. 4. Add the recommended oil as recommended. Select an open area that allows room to maintain the oil level in period. 40 Perform regular checks on fluid levels, controls and areas outlined on page 17. 2. Pull only light loads. 7. Avoid aggressive acceleration and high speed operation during the break-in of the clutches and drive belt will...
Owners Manual
Page 56
... down and drive in rough terrain, while cornering, or while ascending or descending a hill. 52 When handling off-centered loads that cannot be adversely affected, causing the vehicle to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on a level grass surface. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme...
... down and drive in rough terrain, while cornering, or while ascending or descending a hill. 52 When handling off-centered loads that cannot be adversely affected, causing the vehicle to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on a level grass surface. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme...
Owners Manual
Page 59
... a trailer to the trailer hitch bracket only. Model RANGER 4X4 RANGER CREW Total Towed Load Weight (Level Ground) 1250 lbs. (567 kg) 1250 lbs. (567 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) 10 mph (16 kph) Belt Life To extend belt...
... a trailer to the trailer hitch bracket only. Model RANGER 4X4 RANGER CREW Total Towed Load Weight (Level Ground) 1250 lbs. (567 kg) 1250 lbs. (567 kg) Total Towed Load Weight (15° grade) 850 lbs. (386 kg) 850 lbs. (386 kg) Total Hitch Vertical Weight 150 lbs. (68.1 kg) 150 lbs. (68.1 kg) Maximum Towing Speed 10 mph (16 kph) 10 mph (16 kph) Belt Life To extend belt...
Owners Manual
Page 61
... disengage until the engine RPM is below 3100. If the rear wheels are spinning may remain in AWD. NOTICE: Switching to AWD while the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 57 This condition causes increased steering effort and some vehicle speed restriction. Stop completely. 4. When the rear wheels regain traction, the front gearcase will automatically engage any time the rear wheels lose traction...
... disengage until the engine RPM is below 3100. If the rear wheels are spinning may remain in AWD. NOTICE: Switching to AWD while the rear wheels are spinning, release the throttle before getting into low gear and drive forward. 57 This condition causes increased steering effort and some vehicle speed restriction. Stop completely. 4. When the rear wheels regain traction, the front gearcase will automatically engage any time the rear wheels lose traction...
Owners Manual
Page 65
...X General lubrication Shift Linkage n Steering X Front Suspension X Rear Suspension nE Throttle cable E Throttle body air intake ducts/flange Drive belt Cooling system (if applicable) X Engine oil change X Oil filter change at one month Lubricate all fittings, pivots, cables, etc. lubricate; change yearly Inspect; replace as needed Inspect coolant strength seasonally; n Have an authorized POLARIS dealer perform these procedures more often for proper sealing/air leaks Inspect; change yearly Inspect level; adjust; change yearly Inspect level; change yearly Inspect...
...X General lubrication Shift Linkage n Steering X Front Suspension X Rear Suspension nE Throttle cable E Throttle body air intake ducts/flange Drive belt Cooling system (if applicable) X Engine oil change X Oil filter change at one month Lubricate all fittings, pivots, cables, etc. lubricate; change yearly Inspect; replace as needed Inspect coolant strength seasonally; n Have an authorized POLARIS dealer perform these procedures more often for proper sealing/air leaks Inspect; change yearly Inspect level; adjust; change yearly Inspect level; change yearly Inspect...
Owners Manual
Page 66
... M X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E n Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M - clean; E Emission-Related Service. n Have an authorized POLARIS dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, pump, throttle body; replace worn parts Inspect; adjust when parts are replaced Inspect daily; apply dielectric grease to connectors subjected to severe use. X Wiring n Clutches (drive 100...
... M X Radiator (in applicable) X Cooling Hoses X Engine mounts Exhaust muffler/ pipe X Spark plug E n Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M - clean; E Emission-Related Service. n Have an authorized POLARIS dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, pump, throttle body; replace worn parts Inspect; adjust when parts are replaced Inspect daily; apply dielectric grease to connectors subjected to severe use. X Wiring n Clutches (drive 100...
Owners Manual
Page 93
... transmission in PARK. Do not service axle nuts that all nuts are torqued to specification. Place the transmission in PARK. 2. Be sure the valve stem is toward forward rotation. Carefully lower the vehicle to specification. Always ensure that have a cotter pin installed. Attach the wheel nuts and washers and finger tighten. 4. WARNING! Remove the wheel. Place the wheel in serious injury or death. Apply the brakes...
... transmission in PARK. Do not service axle nuts that all nuts are torqued to specification. Place the transmission in PARK. 2. Be sure the valve stem is toward forward rotation. Carefully lower the vehicle to specification. Always ensure that have a cotter pin installed. Attach the wheel nuts and washers and finger tighten. 4. WARNING! Remove the wheel. Place the wheel in serious injury or death. Apply the brakes...
Owners Manual
Page 94
... the wiring. 3. CAUTION! Reinstall the harness assembly into the headlight assembly. 90 MAINTENANCE Lights Poor lighting can cause burns to skin. Oil from the wiring harness. Open the hood. Unplug the headlamp from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. When servicing a halogen lamp, don't touch the lamp with bare fingers. Clean lights frequently and replace burned...
... the wiring. 3. CAUTION! Reinstall the harness assembly into the headlight assembly. 90 MAINTENANCE Lights Poor lighting can cause burns to skin. Oil from the wiring harness. Open the hood. Unplug the headlamp from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. When servicing a halogen lamp, don't touch the lamp with bare fingers. Clean lights frequently and replace burned...
Owners Manual
Page 95
... a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the ON position. 2. If a headlight needs adjustment, locate the adjustment screw at the same height. 3. Turn the ignition switch to the center of pedal travel. Apply the brakes. Turn on after about 10mm (0.4 in.) of the headlight and make a mark on , check the bulb. 91 MAINTENANCE Lights Headlight Beam Adjustment X X 8" (20 cm...
... a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the ON position. 2. If a headlight needs adjustment, locate the adjustment screw at the same height. 3. Turn the ignition switch to the center of pedal travel. Apply the brakes. Turn on after about 10mm (0.4 in.) of the headlight and make a mark on , check the bulb. 91 MAINTENANCE Lights Headlight Beam Adjustment X X 8" (20 cm...
Owners Manual
Page 108
Turning Radius Towing Capacity Hitch Tongue Capacity Max. Dual A-arm w/9.6 in. (24.4 cm) of travel (24.4 cm) of travel Independent w/9 in. (23 Independent w/9 in . SPECIFICATIONS RANGER 500 EFI 4X4 Maximum Weight Capacity (includes weight of travel 104 Cargo Box Load Engine Displacement Bore x Stroke (mm) Alternator Output Compression Ratio Starting System Fuel System Ignition Timing Spark Plug Lubrication System Cooling Front Suspension Rear Suspension 1000 lbs. (454 kg) RANGER 500 EFI CREW 1250 lbs. (567 kg) 1055 lbs. (478.5 kg...
Turning Radius Towing Capacity Hitch Tongue Capacity Max. Dual A-arm w/9.6 in. (24.4 cm) of travel (24.4 cm) of travel Independent w/9 in. (23 Independent w/9 in . SPECIFICATIONS RANGER 500 EFI 4X4 Maximum Weight Capacity (includes weight of travel 104 Cargo Box Load Engine Displacement Bore x Stroke (mm) Alternator Output Compression Ratio Starting System Fuel System Ignition Timing Spark Plug Lubrication System Cooling Front Suspension Rear Suspension 1000 lbs. (454 kg) RANGER 500 EFI CREW 1250 lbs. (567 kg) 1055 lbs. (478.5 kg...
Owners Manual
Page 116
... to the following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components 112 If you have not signed the original registration and received the customer copy, please contact your warranty coverage. Warranty does not apply to parts...
... to the following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components 112 If you have not signed the original registration and received the customer copy, please contact your warranty coverage. Warranty does not apply to parts...
Owners Manual
Page 121
...; Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for your vehicle. POLARIS Industries Inc. The warranty period for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of the vehicle owner. POLARIS...
...; Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for your vehicle. POLARIS Industries Inc. The warranty period for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of the vehicle owner. POLARIS...
Owners Manual
Page 127
... Exhaust System Warning ...82 F Fouled Plugs ...73 Freeplay Adjustment, Throttle ...85 Freeplay, Throttle ...84 Front Gearcase ...70-71 Fuel Cap ...29 Fuel Safety ...17 Fuel Stabilizer ...101 Fuel Tank Filler Cap ...29 Fuses ...97 G Gap, Spark Plug ...72 Gasoline Handling ...17 Gear Circuit Diagnostics...35 Gear Selector ...23 Gearcase Specification Chart ...68 Gearcase, Front ...70-71 Gearcase, Main ...69 Gearcases ...68-71 Gears, Shifting ...23 F Filter Systems ...80-81 Filter, Air ...80 Filter, Breather ...81 Fluid, Battery ...95 Fluid Change Engine Oil...
... Exhaust System Warning ...82 F Fouled Plugs ...73 Freeplay Adjustment, Throttle ...85 Freeplay, Throttle ...84 Front Gearcase ...70-71 Fuel Cap ...29 Fuel Safety ...17 Fuel Stabilizer ...101 Fuel Tank Filler Cap ...29 Fuses ...97 G Gap, Spark Plug ...72 Gasoline Handling ...17 Gear Circuit Diagnostics...35 Gear Selector ...23 Gearcase Specification Chart ...68 Gearcase, Front ...70-71 Gearcase, Main ...69 Gearcases ...68-71 Gears, Shifting ...23 F Filter Systems ...80-81 Filter, Air ...80 Filter, Breather ...81 Fluid, Battery ...95 Fluid Change Engine Oil...
Owners Manual
Page 129
..., Battery ...95 Storage, Covers ...102 Storage, Removal from ...103 Switches ...24-25 AWD Switch...25 Differential Lock Switch ...25 Ignition Switch ...24 Light Switch ...24 T Tachometer ...33, 35 Throttle Freeplay ...84 Throttle Freeplay Adjustment...85 Throttle Freeplay Inspection...84 Throttle Pedal ...25 Throttle System...84-85 Tires ...88-89 Nut Torque ...88 Tread Depth ...88 Wheel Installation ...89 Wheel Removal ...89 Torque, Spark Plug ...72 Towing Loads ...55 Towing Speed ...55 Trailer Hitch Bracket ...21 Transmission...69 Transmission Operation...
..., Battery ...95 Storage, Covers ...102 Storage, Removal from ...103 Switches ...24-25 AWD Switch...25 Differential Lock Switch ...25 Ignition Switch ...24 Light Switch ...24 T Tachometer ...33, 35 Throttle Freeplay ...84 Throttle Freeplay Adjustment...85 Throttle Freeplay Inspection...84 Throttle Pedal ...25 Throttle System...84-85 Tires ...88-89 Nut Torque ...88 Tread Depth ...88 Wheel Installation ...89 Wheel Removal ...89 Torque, Spark Plug ...72 Towing Loads ...55 Towing Speed ...55 Trailer Hitch Bracket ...21 Transmission...69 Transmission Operation...