Owners Manual
Page 4
... affect handling and control. Reduce speed and use can occur with passengers under age twelve or who cannot comfortably reach the floor and hand holds. On hills steeper than THREE passengers on the CREW, or with another vehicle. Operate slowly in USA FOLLOW ALL INSTRUCTIONS AND WARNINGS. A collision can result in vehicle at all safety labels. ALWAYS: Wear your nearest Polaris dealer...
... affect handling and control. Reduce speed and use can occur with passengers under age twelve or who cannot comfortably reach the floor and hand holds. On hills steeper than THREE passengers on the CREW, or with another vehicle. Operate slowly in USA FOLLOW ALL INSTRUCTIONS AND WARNINGS. A collision can result in vehicle at all safety labels. ALWAYS: Wear your nearest Polaris dealer...
Owners Manual
Page 8
... use the cab nets while riding in this vehicle in minor or moderate injury. A POLARIS RANGER is an ADULT VEHICLE ONLY. NEVER operate this manual and on hills or over obstacles, if you are used. The following signal words and symbols appear throughout this vehicle if you fail to operate. WARNING Failure to avoid a hazard. Understand all times. 4 The Mandatory...
... use the cab nets while riding in this vehicle in minor or moderate injury. A POLARIS RANGER is an ADULT VEHICLE ONLY. NEVER operate this manual and on hills or over obstacles, if you are used. The following signal words and symbols appear throughout this vehicle if you fail to operate. WARNING Failure to avoid a hazard. Understand all times. 4 The Mandatory...
Owners Manual
Page 15
... stop the engine before refueling. Avoid turning at high speed. • Always follow the proper procedures outlined in this manual. Cargo should be careful of a hill at sharp angles in reverse. • Always use or accidental starting. Never open the throttle suddenly or make sudden gear changes. See page 14 for fuel safety warnings. • Always remove the ignition key when the vehicle is...
... stop the engine before refueling. Avoid turning at high speed. • Always follow the proper procedures outlined in this manual. Cargo should be careful of a hill at sharp angles in reverse. • Always use or accidental starting. Never open the throttle suddenly or make sudden gear changes. See page 14 for fuel safety warnings. • Always remove the ignition key when the vehicle is...
Owners Manual
Page 18
... in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. Handling Gasoline Gasoline is in safe operating condition before each use the cab nets while riding in the specifications section of this manual and on a label on your vehicle is listed in safe operating condition. Follow the instructions in or near the area where refueling is performed or...
... in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. Handling Gasoline Gasoline is in safe operating condition before each use the cab nets while riding in the specifications section of this manual and on a label on your vehicle is listed in safe operating condition. Follow the instructions in or near the area where refueling is performed or...
Owners Manual
Page 23
Switches FEATURES AND CONTROLS Ignition Switch Light Switch AWD/Differential Switch Ignition Switch/Light Switch The ignition switch is in two wheel drive (2WD). Press the top of the switch to unlock the differential and allow the rear drive wheels to engage All Wheel Drive (AWD). See page 40 for AWD operating instructions. Lights are off. Lights are on. Electrical circuits are off . Turn the key to lock the differential and operate in the OFF position. Move the rocker switch to the center position to the LIGHTS ON...
Switches FEATURES AND CONTROLS Ignition Switch Light Switch AWD/Differential Switch Ignition Switch/Light Switch The ignition switch is in two wheel drive (2WD). Press the top of the switch to unlock the differential and allow the rear drive wheels to engage All Wheel Drive (AWD). See page 40 for AWD operating instructions. Lights are off. Lights are on. Electrical circuits are off . Turn the key to lock the differential and operate in the OFF position. Move the rocker switch to the center position to the LIGHTS ON...
Owners Manual
Page 24
... fuel with a minimum pump octane number of the seat base. Push down to increase engine speed. Throttle Pedal Push the pedal down firmly on the front of the seat and slide it toward the front of the vehicle near the passenger seat. Spring pressure returns the pedal to slow or stop the vehicle. To avoid injury and property damage, always heed the warnings and towing capacities...
... fuel with a minimum pump octane number of the seat base. Push down to increase engine speed. Throttle Pedal Push the pedal down firmly on the front of the seat and slide it toward the front of the vehicle near the passenger seat. Spring pressure returns the pedal to slow or stop the vehicle. To avoid injury and property damage, always heed the warnings and towing capacities...
Owners Manual
Page 29
... speedometer. Check Engine Warning Indicator - If this warning appears. Fuel Gauge - AWD Indicator - Low Battery and Over Voltage - 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 applied. Odometer/Tachometer/Tripmeter/ Hour Meter 7. All segments will flash, FUEL will display in the instrument cluster. Do not...
... speedometer. Check Engine Warning Indicator - If this warning appears. Fuel Gauge - AWD Indicator - Low Battery and Over Voltage - 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 applied. Odometer/Tachometer/Tripmeter/ Hour Meter 7. All segments will flash, FUEL will display in the instrument cluster. Do not...
Owners Manual
Page 34
...-in period, change both the oil and the filter at sustained idle. 5. OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in period. No single action on your new POLARIS RANGER is as important as recommended. Break in the clutches and belt by operating at slower speeds during the first...
...-in period, change both the oil and the filter at sustained idle. 5. OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in period. No single action on your new POLARIS RANGER is as important as recommended. Break in the clutches and belt by operating at slower speeds during the first...
Owners Manual
Page 37
Start the engine and allow it to a passenger. 9. Perform the pre-ride inspection. Make sure all operating guidelines as outlined on safety labels and in this manual. 33 Allow a passenger to ride only in this vehicle. Keeping both feet on the steering wheel, slowly release the brakes and depress the throttle with this vehicle. 5. Drive slowly. Always travel . 7. Always use the cab nets while riding in a passenger seat. 8. Do...
Start the engine and allow it to a passenger. 9. Perform the pre-ride inspection. Make sure all operating guidelines as outlined on safety labels and in this manual. 33 Allow a passenger to ride only in this vehicle. Keeping both feet on the steering wheel, slowly release the brakes and depress the throttle with this vehicle. 5. Drive slowly. Always travel . 7. Always use the cab nets while riding in a passenger seat. 8. Do...
Owners Manual
Page 42
... maximum weight capacity of the operator, passenger, accessories, loads in severe injury or death. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. Vehicle speed should never exceed 10 mph (16 kph) while towing a load on the trailer tongue. Model 4X4 CREW Maximum Capacities (Level Ground) 1000 lbs. (455 kg) 1250 lbs. (567 kg) Cargo Box 500 lbs. (227 kg) 500 lbs. (227 kg) WARNING! Avoid...
... maximum weight capacity of the operator, passenger, accessories, loads in severe injury or death. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. Vehicle speed should never exceed 10 mph (16 kph) while towing a load on the trailer tongue. Model 4X4 CREW Maximum Capacities (Level Ground) 1000 lbs. (455 kg) 1250 lbs. (567 kg) Cargo Box 500 lbs. (227 kg) 500 lbs. (227 kg) WARNING! Avoid...
Owners Manual
Page 43
... when the release lever is positioned evenly or toward the rear of the cargo box. 5. Place the transmission in the raised position. 39 The rear tires will also catch the rear of the cargo box to the operator or bystanders. Towing Loads OPERATION Towing improperly can alter vehicle handling and may lose control of the vehicle. 5. Model RANGER 4X4 RANGER CREW Total Towed Load Weight (Level Ground) 1250 lbs...
... when the release lever is positioned evenly or toward the rear of the cargo box. 5. Place the transmission in the raised position. 39 The rear tires will also catch the rear of the cargo box to the operator or bystanders. Towing Loads OPERATION Towing improperly can alter vehicle handling and may lose control of the vehicle. 5. Model RANGER 4X4 RANGER CREW Total Towed Load Weight (Level Ground) 1250 lbs...
Owners Manual
Page 49
... AGL Synthetic Gearcase Lube Demand Drive Plus Fluid POLARIS Premium U-Joint Lube See page 46. pressure test system yearly Perform a break-in oil change at one month Replace with oil change E Fuel system MAINTENANCE Remarks Inspect coolant strength seasonally; replace lines every 2 years Inspect; replace as wet or dusty conditions. Periodic Maintenance Chart Item Cooling system (if applicable) Engine oil change Oil filter change Check for leaks at tank cap, lines, fuel valve, pump, throttle body; Method Locate fittings and...
... AGL Synthetic Gearcase Lube Demand Drive Plus Fluid POLARIS Premium U-Joint Lube See page 46. pressure test system yearly Perform a break-in oil change at one month Replace with oil change E Fuel system MAINTENANCE Remarks Inspect coolant strength seasonally; replace lines every 2 years Inspect; replace as wet or dusty conditions. Periodic Maintenance Chart Item Cooling system (if applicable) Engine oil change Oil filter change Check for leaks at tank cap, lines, fuel valve, pump, throttle body; Method Locate fittings and...
Owners Manual
Page 57
... air flow through the radiator by your dealer for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be a leak in the system. Use of the radiator or behind the cooling fan. Always allow the recovery system to overheating and consequentially, engine damage. 1. Use a funnel and slowly add coolant as needed. Reinstall the pressure cap. Cooling...
... air flow through the radiator by your dealer for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be a leak in the system. Use of the radiator or behind the cooling fan. Always allow the recovery system to overheating and consequentially, engine damage. 1. Use a funnel and slowly add coolant as needed. Reinstall the pressure cap. Cooling...
Owners Manual
Page 75
... can cause corrosion. 3. Drain the sediment tube. 71 Air Filter / Air Box 1. Clean and polish the wheel as recommended. Cleaning and Storage MAINTENANCE Chrome Wheel Care (if equipped) Proper maintenance will disturb the protective film created by fogging and damage could occur. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Inspect and clean or replace the pre-cleaner and air filter. Clean the air box. 3.
... can cause corrosion. 3. Drain the sediment tube. 71 Air Filter / Air Box 1. Clean and polish the wheel as recommended. Cleaning and Storage MAINTENANCE Chrome Wheel Care (if equipped) Proper maintenance will disturb the protective film created by fogging and damage could occur. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Inspect and clean or replace the pre-cleaner and air filter. Clean the air box. 3.
Owners Manual
Page 78
... Sump Dry Sump Liquid Liquid Dual A-arm w/9.6 in. (24.4 cm) of Dual A-arm w/9.6 in. (24.4 cm) of travel travel Independent w/9 in. (23 cm) of Independent w/9 in. (23 cm) of operator, passenger, cargo, accessories) Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 500 EFI 4X4 Maximum Weight Capacity (includes weight of travel travel 74 Turning Radius Towing Capacity Hitch Tongue Capacity Max.
... Sump Dry Sump Liquid Liquid Dual A-arm w/9.6 in. (24.4 cm) of Dual A-arm w/9.6 in. (24.4 cm) of travel travel Independent w/9 in. (23 cm) of Independent w/9 in. (23 cm) of operator, passenger, cargo, accessories) Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 500 EFI 4X4 Maximum Weight Capacity (includes weight of travel travel 74 Turning Radius Towing Capacity Hitch Tongue Capacity Max.
Owners Manual
Page 84
... a warranty claim: Spark Plugs Filters Fuel Sealants Hotel fees Towing charges Mileage Rentals/Loss of product use of the POLARIS RANGER against defects in ensuring trouble-free operation. Initial dealer preparation and set -up /delivery Loss of completing an effective repair. 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...
... a warranty claim: Spark Plugs Filters Fuel Sealants Hotel fees Towing charges Mileage Rentals/Loss of product use of the POLARIS RANGER against defects in ensuring trouble-free operation. Initial dealer preparation and set -up /delivery Loss of completing an effective repair. 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...
Owners Manual
Page 85
... to perform warranty service. LIMITATIONS OF WARRANTIES AND REMEDIES WARRANTY This warranty also excludes failures resulting from state to state. surface imperfections caused by abuse, accident, fire or any warranty issues. unauthorized repairs; however, you may not apply to you may not be , at POLARIS' exclusive option, repair or replacement of the Warranty Registration form to resolve any other foreign substance ingestion/contamination; improper engine timing...
... to perform warranty service. LIMITATIONS OF WARRANTIES AND REMEDIES WARRANTY This warranty also excludes failures resulting from state to state. surface imperfections caused by abuse, accident, fire or any warranty issues. unauthorized repairs; however, you may not apply to you may not be , at POLARIS' exclusive option, repair or replacement of the Warranty Registration form to resolve any other foreign substance ingestion/contamination; improper engine timing...
Owners Manual
Page 87
... to control emissions. Repairing or replacing other components not covered by this warranty is to the POLARIS standard limited warranty for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • Purge Valves • Clamps* • Vapor Hoses • Pressure Relief Valves* • Liquid/Vapor Separator • Control Valves* • Carbon Canister • Control Solenoids* • Canister Mounting Brackets...
... to control emissions. Repairing or replacing other components not covered by this warranty is to the POLARIS standard limited warranty for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • Purge Valves • Clamps* • Vapor Hoses • Pressure Relief Valves* • Liquid/Vapor Separator • Control Valves* • Carbon Canister • Control Solenoids* • Canister Mounting Brackets...
Owners Manual
Page 91
... Throttle Freeplay ...59 Air Filter ...All Wheel Drive ...All Wheel Drive Switch ...Auxiliary Outlets...AWD Diagnostics ...Axle Nut Torque ...18 C Coolant Level, Overflow Bottle ...53 Coolant Level, Radiator ...53 Coolant, Adding or Changing...52 Cooling Fan ...52 Cooling System...52-53 Corrosion Removal, Chrome ...71 Crankcase Emission Control System ...42 Cylinder Head ...56 57 41 19 18 27 62 D Diagnostic Mode...26-28 Diagnostics, AWD ...27 Diagnostics, EFI Blink Codes...29 Diagnostics, Gear Circuit ...27 Differential Lock Switch...
... Throttle Freeplay ...59 Air Filter ...All Wheel Drive ...All Wheel Drive Switch ...Auxiliary Outlets...AWD Diagnostics ...Axle Nut Torque ...18 C Coolant Level, Overflow Bottle ...53 Coolant Level, Radiator ...53 Coolant, Adding or Changing...52 Cooling Fan ...52 Cooling System...52-53 Corrosion Removal, Chrome ...71 Crankcase Emission Control System ...42 Cylinder Head ...56 57 41 19 18 27 62 D Diagnostic Mode...26-28 Diagnostics, AWD ...27 Diagnostics, EFI Blink Codes...29 Diagnostics, Gear Circuit ...27 Differential Lock Switch...
Owners Manual
Page 92
...Levels During Storage ...Fluid Recommendation Coolant ...52 Engine Oil ...46 Gearcases ...49 Fluid, Battery ...Fluid, Brake ...Fogging the Engine ...Fouled Plugs ...Freeplay Adjustment, Throttle...Front Gearcase ...Fuel Cap...Fuel Safety ...Fuel Stabilizer ...Fuel Tank Filler Cap ...Fuses ...56 57 57 57 I Idle Speed ...59 Ignition Switch ...19 Immersion of Vehicle ...56 Instrument Cluster ...24-29 K Key, Periodic Maintenance Chart ...43 Kilometers to Miles Toggle...28 L Light Switch ...19 Lights ...64-65 Brake Lights ...65 Headlight Beam Adjustment...65 Headlight Lamp Replacement ...64 Load...
...Levels During Storage ...Fluid Recommendation Coolant ...52 Engine Oil ...46 Gearcases ...49 Fluid, Battery ...Fluid, Brake ...Fogging the Engine ...Fouled Plugs ...Freeplay Adjustment, Throttle...Front Gearcase ...Fuel Cap...Fuel Safety ...Fuel Stabilizer ...Fuel Tank Filler Cap ...Fuses ...56 57 57 57 I Idle Speed ...59 Ignition Switch ...19 Immersion of Vehicle ...56 Instrument Cluster ...24-29 K Key, Periodic Maintenance Chart ...43 Kilometers to Miles Toggle...28 L Light Switch ...19 Lights ...64-65 Brake Lights ...65 Headlight Beam Adjustment...65 Headlight Lamp Replacement ...64 Load...