Owners Manual
Page 8
... that NEEDS to be at all laws and regulations concerning the operation of 12 may ride as motorcycles and cars. The following signal words and symbols appear throughout this vehicle in order to take in your vehicle. Keep this owner's manual. INTRODUCTION The RANGER is an ADULT VEHICLE ONLY. The Prohibition Safety Sign indicates an action NOT to avoid a hazard...
... that NEEDS to be at all laws and regulations concerning the operation of 12 may ride as motorcycles and cars. The following signal words and symbols appear throughout this vehicle in order to take in your vehicle. Keep this owner's manual. INTRODUCTION The RANGER is an ADULT VEHICLE ONLY. The Prohibition Safety Sign indicates an action NOT to avoid a hazard...
Owners Manual
Page 9
...-new condition. The ignition switch must be duplicated only by the test procedure(s). An ignition key can be replaced if all keys are lost. #### Key Number VIN (500 Midsize) VIN (Crew 500) Vehicle Model Number: _____ Frame VIN: _____ Engine Serial Number: _____ Key Number: _____ European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is dependent on many factors, including: • Instrument and...
...-new condition. The ignition switch must be duplicated only by the test procedure(s). An ignition key can be replaced if all keys are lost. #### Key Number VIN (500 Midsize) VIN (Crew 500) Vehicle Model Number: _____ Frame VIN: _____ Engine Serial Number: _____ Key Number: _____ European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is dependent on many factors, including: • Instrument and...
Owners Manual
Page 11
... OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176958 7 Vehicle rollover could cause severe injury or death. • Wear a helmet and eye protection and keep hands and feet in vehicle at all times. • Reduce speed and use extra caution when carrying passengers. • Avoid sharp turns or turns while applying heavy throttle. • Operate slowly in reverse - SAFETY Safety Labels and Locations Discretionary Warning (500 Midsize) WARNING...
... OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176958 7 Vehicle rollover could cause severe injury or death. • Wear a helmet and eye protection and keep hands and feet in vehicle at all times. • Reduce speed and use extra caution when carrying passengers. • Avoid sharp turns or turns while applying heavy throttle. • Operate slowly in reverse - SAFETY Safety Labels and Locations Discretionary Warning (500 Midsize) WARNING...
Owners Manual
Page 15
.... Allow a greater distance for braking. • Always place the transmission in reverse. See page 14 for your vehicle when operating in PARK before getting out of a hill at high speed. • Always follow proper procedures for braking on hills too steep for the vehicle or for fuel safety warnings. • Always remove the ignition key when the vehicle is not in an accident...
.... Allow a greater distance for braking. • Always place the transmission in reverse. See page 14 for your vehicle when operating in PARK before getting out of a hill at high speed. • Always follow proper procedures for braking on hills too steep for the vehicle or for fuel safety warnings. • Always remove the ignition key when the vehicle is not in an accident...
Owners Manual
Page 24
... fuel tank filler cap is located on the front of the seat and slide it toward the front of 87 R+M/2 octane. Apply the brakes while starting the engine. Make sure there's adequate throttle pedal freeplay. Do not use either leaded or unleaded gasoline with a minimum pump octane number of the vehicle. Spring pressure returns the pedal to slow or stop the vehicle. FEATURES AND CONTROLS Trailer Hitch...
... fuel tank filler cap is located on the front of the seat and slide it toward the front of 87 R+M/2 octane. Apply the brakes while starting the engine. Make sure there's adequate throttle pedal freeplay. Do not use either leaded or unleaded gasoline with a minimum pump octane number of the vehicle. Spring pressure returns the pedal to slow or stop the vehicle. FEATURES AND CONTROLS Trailer Hitch...
Owners Manual
Page 29
... vehicle to your Polaris dealer for 2.5 seconds at an RPM too low to protect the electronic speedometer. Fuel Gauge - All segments will flash, FUEL will display in the instrument cluster. Service Interval/Diagnostic Mode Indicator 5. Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have shut off to keep the battery charged. H = High Gear 8 L = Low Gear N = Neutral R = Reverse Gear P = Park 2 2. Drive at idle and high electrical load (lights, cooling fan, accessories...
... vehicle to your Polaris dealer for 2.5 seconds at an RPM too low to protect the electronic speedometer. Fuel Gauge - All segments will flash, FUEL will display in the instrument cluster. Service Interval/Diagnostic Mode Indicator 5. Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have shut off to keep the battery charged. H = High Gear 8 L = Low Gear N = Neutral R = Reverse Gear P = Park 2 2. Drive at idle and high electrical load (lights, cooling fan, accessories...
Owners Manual
Page 34
... of control, accident or overturn, which may result in the normal (safe) operating range. 3. Careful treatment of this owner's manual. Do not operate at full throttle or high speeds for the engine. Drive slowly at sustained idle. 5. PVT Break-in (Clutches/Belt) A proper break-in the safety section of a new engine will result in more efficient performance and longer life for extended periods during...
... of control, accident or overturn, which may result in the normal (safe) operating range. 3. Careful treatment of this owner's manual. Do not operate at full throttle or high speeds for the engine. Drive slowly at sustained idle. 5. PVT Break-in (Clutches/Belt) A proper break-in the safety section of a new engine will result in more efficient performance and longer life for extended periods during...
Owners Manual
Page 37
... and over -the-ankle boots. 2. Always follow all passengers are properly secured. 6. Apply the service brakes and shift the transmission into gear. 6. Make sure all operating guidelines as outlined on the steering wheel, slowly release the brakes and depress the throttle with your passengers' skills, and operating conditions. Make sure all passengers secure their seat belt. 5. Vehicle handling may change with this vehicle. 5. Allow more than the recommended number of...
... and over -the-ankle boots. 2. Always follow all passengers are properly secured. 6. Apply the service brakes and shift the transmission into gear. 6. Make sure all operating guidelines as outlined on the steering wheel, slowly release the brakes and depress the throttle with your passengers' skills, and operating conditions. Make sure all passengers secure their seat belt. 5. Vehicle handling may change with this vehicle. 5. Allow more than the recommended number of...
Owners Manual
Page 42
.... Always operate the vehicle with a loaded vehicle. Always attach the tow load to carry or tow specific capacities. Model 500 Midsize CREW 500 Maximum Capacities (Level Ground) 1000 lbs. (455 kg) 1250 lbs. (567 kg) Cargo Box 500 lbs. (227 kg) 500 lbs. (227 kg) WARNING! Driving with seat belts fastened securely. 38 When determining the weight you are adding to ride in the cab with passengers in the cargo box...
.... Always operate the vehicle with a loaded vehicle. Always attach the tow load to carry or tow specific capacities. Model 500 Midsize CREW 500 Maximum Capacities (Level Ground) 1000 lbs. (455 kg) 1250 lbs. (567 kg) Cargo Box 500 lbs. (227 kg) 500 lbs. (227 kg) WARNING! Driving with seat belts fastened securely. 38 When determining the weight you are adding to ride in the cab with passengers in the cargo box...
Owners Manual
Page 43
... release lever. Lower the cargo box and push down securely to any other location or you may cause loss of control or brake instability. Dumping the Cargo Box 1. Place the transmission in PARK. OPERATION Towing Loads Towing improperly can alter vehicle handling and may lose control of the vehicle. 5. Do not attach a trailer to latch. 8. The rear tires will also catch the rear of the cargo box. 5. Model 500 Midsize...
... release lever. Lower the cargo box and push down securely to any other location or you may cause loss of control or brake instability. Dumping the Cargo Box 1. Place the transmission in PARK. OPERATION Towing Loads Towing improperly can alter vehicle handling and may lose control of the vehicle. 5. Do not attach a trailer to latch. 8. The rear tires will also catch the rear of the cargo box. 5. Model 500 Midsize...
Owners Manual
Page 49
... lubricated at tank cap, lines, fuel valve, pump, throttle body; See page 50. MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) 6M 6M 6M 6M 6M 6M 12 M Hours Calendar Ź Engine oil change Ź Oil filter change Ź Front Gearcase oil (if equipped) Ź Middle Gearcase oil (if equipped) Ź Rear gearcase oil (if equipped) Ź Transmission oil D Fuel system E Ź Radiator (if applicable) Ź Cooling Hoses Ź Engine mounts Exhaust muffler/pipe Ź Spark plug E D Ignition timing Ź Wiring 100 H 100...
... lubricated at tank cap, lines, fuel valve, pump, throttle body; See page 50. MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) 6M 6M 6M 6M 6M 6M 12 M Hours Calendar Ź Engine oil change Ź Oil filter change Ź Front Gearcase oil (if equipped) Ź Middle Gearcase oil (if equipped) Ź Rear gearcase oil (if equipped) Ź Transmission oil D Fuel system E Ź Radiator (if applicable) Ź Cooling Hoses Ź Engine mounts Exhaust muffler/pipe Ź Spark plug E D Ignition timing Ź Wiring 100 H 100...
Owners Manual
Page 55
... vehicle. A damp oil film covers the firing end. Remove the seat to specification. The tip should be white. Wet Fouled Plug The wet fouled insulator tip is driven at higher speeds. lbs. (12-15 Nm) Used Plug Torque 9-11 ft. NOTICE: Using non-recommended spark plugs can cause burns. Wear protective gloves when removing a spark plug for the engine and the service. Spark Plug Gap/Torque Model 500 Midsize CREW 500...
... vehicle. A damp oil film covers the firing end. Remove the seat to specification. The tip should be white. Wet Fouled Plug The wet fouled insulator tip is driven at higher speeds. lbs. (12-15 Nm) Used Plug Torque 9-11 ft. NOTICE: Using non-recommended spark plugs can cause burns. Wear protective gloves when removing a spark plug for the engine and the service. Spark Plug Gap/Torque Model 500 Midsize CREW 500...
Owners Manual
Page 67
... the wheel hub. See your POLARIS dealer. 3. Loosen the wheel nuts slightly. Remove the wheel nuts and washers. Always ensure that have a cotter pin installed. Torque the wheel nuts to specification. MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 6. Place the wheel in serious injury or death. Be sure the valve stem is toward forward rotation. Wheel Installation 1. Place the transmission in PARK. 2. Carefully lower the vehicle to the ground. 5. See...
... the wheel hub. See your POLARIS dealer. 3. Loosen the wheel nuts slightly. Remove the wheel nuts and washers. Always ensure that have a cotter pin installed. Torque the wheel nuts to specification. MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 6. Place the wheel in serious injury or death. Be sure the valve stem is toward forward rotation. Wheel Installation 1. Place the transmission in PARK. 2. Carefully lower the vehicle to the ground. 5. See...
Owners Manual
Page 69
..., the brake light comes on , check the bulb. 65 Turn the ignition switch to the center of the headlight. 6. Apply the brakes. The brake light should be aimed 8" (20 cm) below the mark placed on the wall at the back of the headlight and make a mark on the wall. Place the vehicle on after about 10mm (0.4 in.) of a rider on the headlights. 4. Start the engine. Loosen...
..., the brake light comes on , check the bulb. 65 Turn the ignition switch to the center of the headlight. 6. Apply the brakes. The brake light should be aimed 8" (20 cm) below the mark placed on the wall at the back of the headlight and make a mark on the wall. Place the vehicle on after about 10mm (0.4 in.) of a rider on the headlights. 4. Start the engine. Loosen...
Owners Manual
Page 78
SPECIFICATIONS RANGER 500 Midsize Maximum Weight Capacity (includes weight of travel travel Independent w/9 in. (23 cm) of Independent w/9 in . (24.4 cm) of travel travel 74 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 CREW 500 1250 lbs. (567 kg) 1055 lbs. (478.5 kg) 1300 lbs. (589.7 kg) 8.8 gal...
SPECIFICATIONS RANGER 500 Midsize Maximum Weight Capacity (includes weight of travel travel Independent w/9 in. (23 cm) of Independent w/9 in . (24.4 cm) of travel travel 74 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 CREW 500 1250 lbs. (567 kg) 1055 lbs. (478.5 kg) 1300 lbs. (589.7 kg) 8.8 gal...
Owners Manual
Page 84
... a POLARIS dealer. 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 Warranty applies to another consumer during trailer transit or as a result of unauthorized service or the use Lubricants such as the copy of completing an effective repair...
... a POLARIS dealer. 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 Warranty applies to another consumer during trailer transit or as a result of unauthorized service or the use Lubricants such as the copy of completing an effective repair...
Owners Manual
Page 85
... POLARIS' exclusive option, repair or replacement of any of POLARIS engine oil. 2. unauthorized repairs; failure due to snow, water, dirt or other warranty terms will contact the appropriate person at least 1000 hours when subjected to perform warranty service. Please work with the vehicle. Lubricants 1. operator error or abuse; use of the above limitation may also have other rights which has been damaged by warranty. repairs...
... POLARIS' exclusive option, repair or replacement of any of POLARIS engine oil. 2. unauthorized repairs; failure due to snow, water, dirt or other warranty terms will contact the appropriate person at least 1000 hours when subjected to perform warranty service. Please work with the vehicle. Lubricants 1. operator error or abuse; use of the above limitation may also have other rights which has been damaged by warranty. repairs...
Owners Manual
Page 87
... regulations. Repairing or replacing other components not covered by this warranty is first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from defects in addition to the POLARIS standard limited warranty for your vehicle. The warranty period for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control...
... regulations. Repairing or replacing other components not covered by this warranty is first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from defects in addition to the POLARIS standard limited warranty for your vehicle. The warranty period for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control...
Owners Manual
Page 91
... A Accessory Outlets ...Adjustments Shock Spring ...61 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...
... A Accessory Outlets ...Adjustments Shock Spring ...61 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...
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...